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Re: My Puma 1.7, more than a year on (A works in progress)

Posted: Wed Jan 01, 2014 7:32 pm
by tuonokid
Thanks for that. I suppose it helps that I've got plenty of time on my hands :-)
Barry

Re: My Puma 1.7, more than a year on (A works in progress)

Posted: Thu Jan 09, 2014 9:07 pm
by tuonokid
Next up was the horrible rusty mess that was the remains of my spare wheel carrier it really did let down the underside of the car.
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It took about 5 minutes to grind off the 8 spot welds that held the pressed steel cover in place.
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My plan was to replace the cover with one made of aluminium and to fix it on using captive M5 or M6 nuts welded to the carrier frame. So I cut out the apprx 1 mm thick ali sheet to the same dimensions as the steel one.
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Then I started to put the flanges onto the sides of the sheet.
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Then fitting up to the existing frame
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Just to weld the captive nuts on the underside now and fix the sheet using s/s capheads. Also I will have to weld the ali sheet where I had to split it to bend it around sharp corners.
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Re: My Puma 1.7, more than a year on (A works in progress)

Posted: Fri Jan 10, 2014 9:19 am
by CherryVimto
Wow, hats off to you for all your hard work.

Brilliant! Enjoying seeing your progress.

Re: My Puma 1.7, more than a year on (A works in progress)

Posted: Fri Jan 10, 2014 9:57 am
by tuonokid
Thanks again Cherryvimto but I wouldn't have been able to post properly without your help with the photos :-)
Barry

Re: My Puma 1.7, more than a year on (A works in progress)

Posted: Fri Jan 10, 2014 11:50 am
by moondustka
That's nice! Good idea for those wanting to keep the spare wheel carrier.

I chopped mine off and took the spot welded brackets off the bottom of the car :lol:

Re: My Puma 1.7, more than a year on (A works in progress)

Posted: Fri Jan 10, 2014 10:39 pm
by tuonokid
Thanks Moondustka I didn't want to resort to no spare wheel or a can of tyre Gel, I don't trust that stuff.

Anyway managed to get the captive nuts welded onto the frame today

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Then drilled the aluminium plates and mounted the 2 together. Unfortunately I didn't have any S/S caphead bolts but I'm going to the Autosport tomorrow so should get some there.

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Only got to ali weld the rear flange, straighten up some of the folds and de-burr the edges and that's it for now

Re: My Puma 1.7, more than a year on (A works in progress)

Posted: Mon Jan 13, 2014 10:54 pm
by ukpuma
where did you get the front splitter from?

Re: My Puma 1.7, more than a year on (A works in progress)

Posted: Tue Jan 14, 2014 1:27 am
by tuonokid
Hi ukpuma.
I don't know whether you mean the rubber bit or the bib but the rubber bit is just reinforced rubber belt bought from an autojumble that I cut out with a very sharp Stanley knife through the standard bumper rubber strip (for the fixing points) but I made it 2" deeper than the standard one so it's about 95mm of the floor. The bib is a standard bib that I carbon wrapped(to cover deep scratches).
Hope that helps
Barry

Re: My Puma 1.7, more than a year on (A works in progress)

Posted: Thu Jan 16, 2014 1:37 am
by tuonokid
Just about finished the spare wheel hanger now. Come the spring or summer I'll give the frame a coat of etch primer and black or powder coat it. Here's how it looks in place.
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Re: My Puma 1.7, more than a year on (A works in progress)

Posted: Thu Jan 16, 2014 11:36 am
by Wild E. Coyote
Nice. Spare tyre is still original Pirelli P6000? That IS old...

Re: My Puma 1.7, more than a year on (A works in progress)

Posted: Fri Jan 17, 2014 12:27 am
by aberdarepuma
Wow wouldn't of thought about sorting the spare wheel carrier in that way looks the bees knees,, I also have 2 puma spare wheels original fitted tyres lol

Re: My Puma 1.7, more than a year on (A works in progress)

Posted: Fri Jan 17, 2014 1:56 am
by tuonokid
Thanks Guys
I wouldn't have thought anyone would have spotted the tyre but Wild E Coyote you have won the prize :-) It makes sense with the cars total mileage that it is the original plus it still has all the little rubber sticky bits coming out of it to show that it's not been used.
Barry

Re: My Puma 1.7, more than a year on (A works in progress)

Posted: Mon Jan 20, 2014 7:46 pm
by oli8925
Great work on the Puma and some nice fabricating on the carrier. This is going in my inspiration pile for a track Puma as I'd like to deal with all the little bits of rot as you have.

Also liking the classics, I have a project of my own but being a former classic Escort owner you might not approve.
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It's stalled for the past couple of years but once I get a Mini out of the way I'll hopefully start again. Will be getting a Duratec.

Re: My Puma 1.7, more than a year on (A works in progress)

Posted: Mon Jan 20, 2014 8:44 pm
by tuonokid
Thanks Oli.
Not too much of a Vauxhall fan but the HC looks well for it's age. My first 4 wheeled car was a 1969 Viva HB with the slant four 1600 engine. If it's getting a Duratec be aware that the bell housing bolt arrangement is not standard Ford unless you mean an ST170 which says Duratec but is actually a Zetec.
Barry

Re: My Puma 1.7, more than a year on (A works in progress)

Posted: Tue Jan 21, 2014 4:27 am
by RICHARD MANSFIELD2
Hi, That HC looks very clean, there cannot be that many left now.
That HC brings back some memories, I had one once with a 2279cc lump modified big valve head, mod. camshaft, Janspeed system twin 45 Dellortoes (not sure about the spelling) also fitted a droop snoot. What a car that was, wish I still had it. Also with regard to the comment by Wild E. Coyote about the spare. I still have my original spare used only for 5 miles. I also had the original battery that was 13 years old untill last year.
Regards
Richard

Re: My Puma 1.7, more than a year on (A works in progress)

Posted: Tue Jan 21, 2014 9:45 pm
by tuonokid
Hi Richard
Sound like a droop snoot Firenza. Can you remember that bendy allen key you needed to adjust the tappets on that group of engines?
I have a few mechanic friends and they all seem to say that Ford batteries last a long time so they must be pretty good quality.
My Fiesta's 2003 and has 106k on the clock and it's still the original one, same as the Puma.
Barry

Re: My Puma 1.7, more than a year on (A works in progress)

Posted: Tue Jan 21, 2014 11:28 pm
by zinc2000
Love the HC, Viva Oli, looks realy good on minilights, must get some on my "millie" as soon as funds allow

Re: My Puma 1.7, more than a year on (A works in progress)

Posted: Wed Jan 22, 2014 8:56 am
by RICHARD MANSFIELD2
HI,
I think we are going a little off topic here. It was a long time ago I think I was able to use an ordinary allen key. I wish it had been a Firenza. It was a four door Magnam that I put the front onto.
Regards
Richard.

My Puma 1.7, more than a year on (A works in progress)

Posted: Wed Jan 22, 2014 9:04 pm
by tuonokid
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About 12 months ago I bought a Piper exhaust manifold and a sports cat off an FRP owner and then a few weeks later I bought a Piper de-cat system off another seller on Ebay. I asked a few questions on here about fitting the manifold as it seemed to be a bit of a tight fit. Well the answer is to get the car very high and then disconnect the bottom chassis to gearbox stabiliser and the stabiliser to the gearchange remote and then you can rock the engine enough for the manifold to clear the rack/bulkhead and the driveshaft. If this helps instead of jacking the car 3' off the floor I took the lid of a manhole in my drive dropped the manifold down it with some thick string and then backed the car over it. It was a simple matter then to just lift the manifold up into place.

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Anyway I was going to fit the rest of the exhaust system until I found that the flanges to the manifold and the middle section didn't square up to each other. The holes matched but the mating faces were a few degrees out from square so that they would never have sealed. This makes me think that they are made in matched sets, so beware if you buy from different people.
Anyway I had to cut off the flange on the middle section and then tack it into place on the car so it fitted properly and then weld it off the car. I had to be really careful here as Stainless is a sod for distorting if you're not too careful.
Then I had a rethink on the de-cat and decided to use the sports cat to stay legal.
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Sportscat showing low density mesh.

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Standard and sportscat.

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De-cat pipe alongside sports cat with spare flange taken from existing exhaust.

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Flange ground off (again) and pipe marked to be cut.

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Pipe cut and flange in place.

The rear flange of the sportscat is a triangular 3 bolt shape whereas the flange of the back section is diamond shape with 2 bolts so I will have to bore out the existing exhaust flange to match the size of the new system and then weld it onto the back of the sports cat. Then buy a S/S Lambda stub to weld into the middle section just to the rear of the cat. then job done, hopefully.

My Puma 1.7, more than a year on (A works in progress)

Posted: Fri Jan 31, 2014 8:44 pm
by tuonokid
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I had a re-think on using the original exhaust flange as the hole through the middle would have taken forever to bore out and there wouldn't have been enough gasket face left to seal properly so I ordered the right size flanges plus a lambda boss.

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First job was to weld the two bolt flange to the cats 3 bolt flange. Both flanges were 8mm thick so I was going to struggle to weld it with my MIG so I dug out the stick welder tried that for a bit and put it back on the shelf...re-think time!
Eventually I MIG welded down through the bolt holes on the 3 bolt flange onto the back of the two bolt flange and that seemed to work but one of my mates uses a TIG at work so I'll get him to go round it and seal it off just in case.

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Next up was to tack the second flange onto the pipe to the rear of the cat.

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I then had a rethink on the front flange to the cat as it was for a ball type joint and there wasn't enough meat around the flange to seal with the gasket as well as providing a step for gas flow.

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I used a spare piece of exhaust pipe to fill in the joint.

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Then another flange to be welded on, centered by the spare piece of exhaust pipe.

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Then I welded another thinner pipe on the inside of this to centre and help to seal the gasket

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I also tacked on captive nuts as it's a lot easier to take off or put the exhaust back on. I then drilled out the pipe for the lambda boss after cutting the boss to the right length. I'll get my mate to TIG all the way around the flange on this pipe as well, but I'll weld the boss on.

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Boss fixed in place.

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boss welded.Exhaust off to my mate for tigging.

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Cat back from Tigging just needs checking on the car to make sure it's not distorted before I give my mate the back pipe to tig up the flange on that.

Re: My Puma 1.7, more than a year on (A works in progress)

Posted: Tue Feb 04, 2014 9:03 am
by MS-DIY
Wow that's amazing the tons of work you have put in to it Barry!!!
Just thinking about, when you don't have a lift, how many times you are going up and down and all the s... you are getting in your face. Well let's face it we ain't getting any younger and with a project like that you sure as hell don't need any sleeping pils :lol:
Keep on the good work Barry. I wish I had the time and place for a job like that.

Re: My Puma 1.7, more than a year on (A works in progress)

Posted: Tue Feb 04, 2014 9:28 am
by MS-DIY
Maybe a stupid question, hope it's okay since I am a newbie ;-)
Is it not possible to get a 4-2-1 mani with sports cat to bolt right on??
I have put on a 2,5" cat back system and next step would be the manifold.
And I also want to stay legal, so have to have a cat on.

Re: My Puma 1.7, more than a year on (A works in progress)

Posted: Tue Feb 04, 2014 11:25 am
by tuonokid
Hi Martin
Thanks for your comments. I'm not using the car as yet so when it's up in the air for work to be done it stays like that for as long as it needs to.
You're right about the crap in your face. I had to have another visit to the hospital this year to have something dug out of my right eye even though I wear goggles. That's about the fourth time in 30 years....not a pleasant experience.
You're also right about the exhaust systems and my original intention was to run it de-cat so all the bits were bought off Fleabay (cheapskate) but at the last minute I thought I'd stay on the legal side and retro fit the cat even though this system never had one.
Barry

My Puma 1.7, more than a year on (A works in progress)

Posted: Mon Feb 10, 2014 11:07 pm
by tuonokid
Next up was the repairs to the floorpans There was only one seriously rotted bit but I wanted to get rid of all the rot so when I'd previously undersealed the floors I taped off areas that required attention so I could sort them out later.

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Serious rot!

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I didn't want to do the work from underneath the car as it's a mucky dangerous job so I marked out the limits of the patches with a 3mm drill bit like this;
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View from above where I'd be working.

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Tool of choice for working inside the car. A Dremmel type tool with diamond tipped cutting discs.

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And 15 mins later....

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Re: My Puma 1.7, more than a year on (A works in progress)

Posted: Sat Feb 15, 2014 4:34 pm
by moondustka
Good work there. Looks similar to what I had to deal with but mine seemed to be quite large! :lol: