Levaz's 3dr 105 project/daily

[Levaz]

\r\n \r\n So, as i had a spare grille (the primered effort that came on the car originally) and i couldnt get into the garage to continue with my sub box, i started eyeing things up and marking bits out.
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\nI\'ve epoxied all the mesh lugs back onto the back of the grill, then busted out the biro and started marking cutting lines
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[Fr3nchy]

\r\n \r\n Completely removing the middle section? If so be nice to see how this comes out
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\nAlso how easy is fibreglassing? I wanna do a boot build while car is SORN\r\n \r\n

[Levaz]

\r\n \r\n Yea, i see plenty of smooth grilles with the whole lot removed, i wanted something a little different. (See lazy photoshop effort)
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\nFibreglassing isnt too difficult, just takes time and patience. I\'m 2-3 hours into mine and it looks like this lol
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\nFor the boot build might be worth giving this a read
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\nhttp://m.instructables.com/id/How-to...-Box/?ALLSTEPS\r\n \r\n

[Levaz]

\r\n \r\n Got a couple more layers of fibreglass down, hopefully 1 more layer and i\'ll be able to remove it from the car and check for air pockets / internal volumes
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\nAlso made a start on the open mouth grille whilst waiting for the fibreglass to set.
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[Levaz]

\r\n \r\n Had a new toy arrive this morning.
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\nNot sure where to fit it though.
\nDo I remove the standard lighter and fit it in place, or wait until I\'ve got an armrest and fit it in there?
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[Levaz]

\r\n \r\n Got a couple more layers of fibreglass down.
\nThe box should now be strong enough to take out of the car for finishing
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\nHaven\'t fitted my usb socket yet, as i decided it\'s going in the armrest. When i can find one for less than £50!
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\nGot a couple of layers of glass down on the grille, but forgot to take a photo.
\nWill get some next time i\'m working on the car
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[Levaz]

\r\n \r\n A couple of small updates, nothing too drastic
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\nReplaced the lighter socket with a twin usb charging port
\n(Excuse the poor photos)
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\nAnd this arrived yesterday along with the rear bumper heatshield
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\nAnd to fit the bumper trim, these arrived this morning
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\nThen just to top it all off, yesterday i also picked up a set of electric window regulators and a new ZR headlight, to replace the R25 one on the drivers side!
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\nLots of updates to come at the weekend hopefully!\r\n \r\n

[ben]

\r\n \r\n Purple !!
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\nI have the same purple 45 elbow from TB, too!
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\nI am still swaying more to liking the mk1 front bumpers than the mk2, especially smoothed. Look forward to some more updates!\r\n \r\n

[Levaz]

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Purple !!
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\r\nI have the same purple 45 elbow from TB, too!
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\r\nI am still swaying more to liking the mk1 front bumpers than the mk2, especially smoothed. Look forward to some more updates!

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you\'ll love the plans I have for the front bumper I\'m picking up then \r\n \r\n

[xanadu]

\r\n \r\n this looks pretty amazing
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[Levaz]

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this looks pretty amazing

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taa muchly!\r\n \r\n

[Levaz]

\r\n \r\n so, on Saturday this might of happened......
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\n11707595_10155921989745077_1313956634573354020_n.jpg
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\nIt\'s a little on the loud side and quite stiff, so I *might* put the standard centre section back in instead of the race tube (which I think is causing the stiffness issue)\r\n \r\n

[adam4185]

\r\n \r\n Looks like ur back box is touchinh the bumper guard. Might want to space it if u can / have a chance. Melted bumpers not good.\r\n \r\n

[Levaz]

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Looks like ur back box is touchinh the bumper guard. Might want to space it if u can / have a chance. Melted bumpers not good.

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Yea, it is, and it\'s putting a vibration through the car (although that could also be where everything is solid)
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\nGlad I put the heatshield on it when I did!
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\nLooking at it, the only way to space it is going to be by bending the hangers, so I\'ll do that tonight.\r\n \r\n

[adam4185]

\r\n \r\n Yeah try bending the mounts first then if u still get the vibration take the centre out again.\r\n \r\n

[xanadu]

\r\n \r\n wow thats a big tailpipe
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[Levaz]

\r\n \r\n S\'only 5" Xan!
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\nWhen I bought it (2nd hand online) the guy said it was a 5 x 3" oval similar to a Magnex.
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\nfunniest shaped oval I\'ve ever seen!\r\n \r\n

[xanadu]

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S\'only 5" Xan!
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\r\nWhen I bought it (2nd hand online) the guy said it was a 5 x 3" oval similar to a Magnex.
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\r\nfunniest shaped oval I\'ve ever seen!

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that\'s what she said.......
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\r\nIts funny though a large tailpipe suits the ZR
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[adam4185]

\r\n \r\n Hummmm interesting shape.... maybe damaged in transit \r\n \r\n

[Levaz]

\r\n \r\n One of my mates is a metal fabricator, he said he\'d reshape I for me if I wanted.
\ndon\'t think I\'m bothered enough by it though, more by how much tension is on the pipework.
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\nCan feel it vibrating through the steering wheel lol\r\n \r\n

[adam4185]

\r\n \r\n I had a golf a few yrs back and the cat fell off the pipework and rested on the steering rack, or another piece of bodywork under the area. Result was noise beyond anything i have ever heard before or since and vibrations to rival an earthquake.\r\n \r\n

[Levaz]

\r\n \r\n it does indeed!
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\nit looks better than the little pea shooter that was there before.
\nGoing to attack it later with a long bar to \'adjust\' the hangers\r\n \r\n

[xanadu]

\r\n \r\n this is very true.
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\nHow does it sound then, excluding vibrations?
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[Levaz]

\r\n \r\n absolutely immense!
\nIf I remember tonight, i\'ll charge my gopro up and try and get a video on the drive to work tomorrow.\r\n \r\n

[xanadu]

\r\n \r\n cool, i\'ll remember to turn my speakers on then lol
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[Levaz]

\r\n \r\n no need, I remembered to charge the camera.
\nforgot to pick it up as I left though #facepalm\r\n \r\n

[xanadu]

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[Levaz]

\r\n \r\n Been very quiet lately, mainly due to waiting for parts.
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\nI\'ve now got some front fog lights, but I want to wrap them in laminex before I fit them.
\nOrdered it, now sitting by the door waiting for the postie.
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\nI\'ve got electric window regulators, but I haven\'t fitted them yet as I need to activate the circuit in the BCU.
\nAs soon as I pull the manual windows out, I lose the ability to open a window until I can get to the garage, and the way the weathers been lately, I\'d rather not lose that option (no sunroof either!) (sorry John, I know you want the manual setup!)
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\nI\'ve got a ZR headlight to go in to replace the R200 one in the driver side, but was going to hold off fitting that until I\'ve got a new bumper ready to go on.
\nI have managed to fit these autoart clear front indicators though (courtesy of JCAHALL)
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\nIgnore the shit paint, as said, I need a bumper lol
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[Levaz]

\r\n \r\n argh!! disaster has struck!
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\nI knew my waterpump was failing slowly, and my HG was starting to weep over the gearbox, so I\'ve been keeping an eye on it with the plan to limp it through till next weekend (I\'m away today - tues in a hire van) and get it sorted then.
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\nGot 300 meters from my front door and it went full kettle!
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\nSteam, smoke, oil pressure light flashing away, killed the engine and coasted it to the door.
\nGoing to rip the head off when I get home Tuesday and see just how bad it is.\r\n \r\n

[Levaz]

\r\n \r\n result!!
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\nThanks to a local to me K series fan, I\'ve just paid £50 for on a 66k miles 1.4 105 engine with an IB5 box, all gaskets done, recent cambelt and waterpump.
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\nJust need to go collect it \r\n \r\n

[flattop]

\r\n \r\n thats a nice result .\r\n \r\n

[Levaz]

\r\n \r\n Thats what i thought!
\nThe guy selling also has a set of 135 cams on vernier pulleys i may have if the price is right\r\n \r\n

[flattop]

\r\n \r\n ohhh sounds nice . u going to scrap the old engine .\r\n \r\n

[Levaz]

\r\n \r\n Pretty much.
\nMight keep the head and tweak it a little, if it\'s not too gone.
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\nCams, vvc inlet, port matching.
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\nDepends just how warped it is and if its been skimmed before\r\n \r\n

[flattop]

\r\n \r\n just read this sounds interesting ...I have done this to a 1.4 and a 1.6 the 1.4 made just over 130 bhp but that included , a fully reworked head, vvc/ 135 inlet along with 52 mm throttle body. full Janspeed exhaust inc mani and sports cat, full mapping and modified the cam dowels to allow adjustment of the cam timing.\r\n \r\n

[Levaz]

\r\n \r\n 125/130bhp would be nice, but at the same time i am on the lookout for a full 1.8t conversion.
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\nThe replacement 1.4 just happened to come along at the right time and price.
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\nBuilding the other head up is more of an \'i can and i want to\' than an \'i need to\'\r\n \r\n

[flattop]

\r\n \r\n i do like the idea of doing a 1.8t but its having the pennies to do it .\r\n \r\n

[Levaz]

\r\n \r\n I was looking at getting a rear ended zt and breaking what was left, try to recover some of the costs\r\n \r\n

[Levaz]

\r\n \r\n haha, not quite.
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\nI\'ve wanted one for ages.
\nMy daily was a Renaultsport Clio 172, which as much as I love it, hasn\'t been reliable, and is usually broken.
\nAt the time, my wife had a little 106 and was working for herself as a mobile hair stylist and beautician, and couldn\'t fit her massage table in the 106.
\nI was looking at a ZR to replace the clio, and we ended up buying one for her instead, so I inherited the 106 (which I promptly wrote off)
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\nA friend was aware I wanted a ZR, and this one came up at the right price, so I bought it completely blind lol
\nNow we have 2 ZR\'s and a Clio lol\r\n \r\n

[Levaz]

\r\n \r\n Right,
\npicking up the engine and box next Saturday, so getting everything ready for then.
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\nI\'ve already got 5l of OAT coolant,
\nordering some 10/40w sem-synth engine oil later on, will be getting some Castrol Multitrans box oil while I\'m at it.
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\nCan anyone else think of anything worth adding to the list?
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\nEngine has just had a clutch and belts, water pump etc.\r\n \r\n

[xanadu]

this looks pretty amazing