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Paul T

1999 SEiW 1800 Q Zetec - Rebuild & Update

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neptune

Paul where did you order your itg filter from? I have a clearance issue between the fittings and my bonnet. Upside down may solve my issue

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Paul T

A friend of mine, Stuart at Premier Power can get them from ITG - info@premierpowerengines.com, tell him I sent you ;)

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neptune

Thanks Paul

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Paul T

Quick one for the guys who were interested in the dash mounting/stiffness...

For the dash panel I replaced the nyloc nuts (which were a massive pain to hold while fitting/removing the dash) with M5 T nuts, although they are not actually fixed (captive) they sit nicely in the recess behind the dash and mean you don’t need to hold them when tightening/loosening the fasteners. Highly recommended.

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To fix the bottom of the dash I just drilled though the ally stiffening piece, straight through the steel tab and used the same stainless M5 dome head fasteners with a T nut. The dash is absolutely solid with no flex whatsoever:yes:

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Paul T

Lots more done this last couple of weeks ready for spring/summer.

Fitted the Raceline sump, this turned out to be a big job (full details here for anyone looking to do the same), I gave it a new set of bolts, seals and o-rings...and I’m really happy I invested, not only is it a proper, baffled RWD sump for piece of mind on track - it’s also ~60mm shallower than the FWD sump fitted before. This did mean I had to trim the bellhousing which was a horrible job under the car with a hack saw but now the lowest point of the car by far is the chassis hoop which is much more preferable!

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While I was under there I noticed one of the trans mounts was perished and as well as the clutch arm boot, so I replaced this and will order a replacement  rubber mount also (anyone advise part no/suppler?)

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I also stripped and repainted the exhaust bracket and replaced the rubber mount. The more I go over the car I realise that after 20 years most rubber/plastic parts are damaged/perished and need replacement.

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Anything I replace I try to either paint, swap out for stainless and/or give a good coat of copperslip to try and avoid future corrosion.

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I also got my new battery cables (custom made by Electrical Car Services) I was extremely impressed by these guys, they were really helpful on advising cable type via email, provide soldering and crimping service with plastic conduit option, and the cables arrived 48hrs after ordering!...if only all suppliers were that efficient ;)

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A small upgrade but worth a mention - I tarted up my new steering wheel with a custom badge made by Go To Graphics

I pulled apart the unused horn mechanism and bonded a piece of G10 plastic in place, Simon is able to supply any size badge so I ordered 39mm which fits perfectly, very happy with this little mod.

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Last but not least I stripped back all the ally cooling pipes, re-jigged the heater circuit a little to be closer to the exhaust (to aid warm up), painted satin black and ordered a load of black silicone hosing with stainless clips to finish...all plumbed in and so far working great. The engine bay looks loads cleaner now and the silicone hose is a nice finishing touch.

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just need to give everything a good clean, polish and fit some new foam tape now before I get in to cutting the bonnet for the ITG filter fit.

It’s back on the road now and still have plenty of jobs to do but I’m looking forward to finally going to a club meet in an actual Westy this week... and am booked in to Stoneleigh and a couple of track days too...roll on summer! :cool:

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Made a little video to celebrate::black-westy:

 

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Paul T

1 week into driving the car again and can honestly say I’m absolutely loving it. I’ve done around 200 miles and it is running and driving great.

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Of course now I’m properly getting to grips with it I’m finding a few things I want to add/tweak...

Seats - Initially I mounted the new seats on 20mm box section which utilised the original runners in the original position. However after the first few miles I decided the seat position was too high so pulled them out and removed the ally box, moved the runners closer together, trimmed the carpet around the seat rails and mounted the seats direct to the runners. Overall this drops the seat by around 25mm and the position is much more to my liking, the only further tweak I’d like to make is to space the front up 5-10mm to give a more reclined position.

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Fan switch - when I first got the car and was working my way through the engine issues I realised it had never had a working fan switch fitted (the fan was wired into an old temp sensor!), initially I wired a manual switch in, but wanted the autonomy (and safety) of a temp sensing switch so I tried to get hold of a compatible part but with no joy. Because of where it sits (engine out, just before ‘stat) it needs a switch in the range of ~100-105DegC and the standard thread of the housing is 3/8NPT. I couldn’t get anything suitable but found a Stoney Racing sensor 100-90DegC with an M14 thread, so I made an adaptor from a 3/8 ally bung and bonded it to the sensor.

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good job I thought...fits great, so I wire it up to the fan, get the engine up to temp, click - fan comes on but never goes off (doh!)

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I quickly realised that the switch isn’t designed for the electrical load of the fan and should be through a suitable relay :o

So being as I need to install 2 relays for the heated seats, and the horn could do with one too, my next little project will be a bit of wiring (which isn’t my favourite) to add a row of relays to my ECU tray under the dash.

 

Fuel Tank/Surge - Something I'm really struggling with - turn hard into a sharp bend or roundabout and lose fuel pressure. This is a big deal as I'm planning on using it a fair bit on track and need to be able to throw it around. I've decided best plan of attack is to modify the fuel tank to add a sump and possibly some internal baffles and/or open cell foam. I'd also like to change the fuel sender as it dances around a lot due to the slosh. I'm looking at getting one of the marine-type 'dip senders' as these should be far more stable and give flexibility to add foam to the tank without affecting the level reading - I need to act on this now as I have Curborough booked on 17th May and will be gutted if I have to take it easy! :cry:

Exhaust Blow/Fumes - I've really noticed my clothes smell of fumes after driving, originally I assumed this was due to the breathers being open and routed via the trans tunnel, but having fixed this over winter the fumes are still very much present. I'm fairly confident it's not the tailpipe as this is pointed down near the real wheel, what I have noticed is the collector (4 manifold branches into 1) is a fairly crap slide joint with lots of sooting around and audible blow - so I have assumed as this is forward of the cockpit and no doubt amidst a great deal of turbulent air off the wheel, this is likely where the dirty gas is coming from. I thought about modifying the collector but having spoken to other members it seems best to just weld up the joint, so I will be tackling this hopefully in the next few days.

 

One other update was a waterproof cockpit cover from Walker St Clair, seems like a sensible and cost effective way to keep the interior clean and dry when parked up, I did look at the soft bits cover but this was more money and my previous experience with the company wasn’t great so opted for the Walker cover and am very happy with it, the owner Peter is very friendly and communicative, after ordering the cover arrived in two days and does exactly what it says on the tin :yes:

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Paul T

With Curborough in May I decided to start on the fuel tank straight away.

 

I thought about adding a separate tank/swirl pot which would require an additional pump, wiring, space etc

 

But to keep it simple I decided to put a sump in the tank as there is a suitable space under the tank and I can fab the parts up myself and have it welded on next week for less than £50.

 

The sump is basically a tapered box with a baffle plate, it’s works out around  ~1.5 litres in volume and will be below the sender min level.

 

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It sits flush with the rear bodywork and with a new outlet means the old outlet can be used as a return for an injection setup in the future.

 

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When the tank was out I noticed the upper wishbone fixing has been pushing into the clearance recess on one side, so to stop any damage/failure in the future I’ve put two 20mm pieces of 16mm heater hose on the nuts and some foam tape along the chassis tube, for belt and braces I also made up some domed washers (using two sockets in the vice) which I’ll bond in place on the tank after welding.

 

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I actually cut two large baffles out to put in the tank but after cutting the hole for the sump I realised there are already baffles in place...You can also see the standard outlet is around 15mm above the bottom of which obviously isn’t ideal and means it needs around a litre of fuel in the tank before it can properly feed the pump(!)

 

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On the sump the outlet will be as low as possible, I’m just waiting for the weld on fitting to arrive, other than that everything is ready and I have a local welding company lined up to do the work next week, so hopefully I can get the tank fitted back in next weekend.

 

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Paul T

Fuel tank welded up, very happy with the work - done by LG Welding in Stratford (he also does some really nice powder coating which I may we’ll be visiting him again for soon!).

 

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I also bought a VDO fuel sender flange from Merlin Motorsport to add to the tank while the welding was being done, which I will add the dip-type sender to when I re-fit everything before Stoneleigh at the weekend.

 

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The modified washers are now bonded on to protect the tank too...

 

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I did a little test to see how the sump works with a simulated ~1g corner...😁

 

 

looks good, constant flow from new feed, (this was with less than 5 litres in the tank which is less that I’d ever intentionally run).

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BugMan

What a great solution, and looks like it will work well, +1 :westy:

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Tim (TimDave25) - Joint Thames Valley AO

I like the simulation 🤣

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AdamR

Nice solution that, I'm also a big fan of doing stuff differently and moving away from 'because it's always been like that'! :t-up:

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mrsntw

@Paul T Great restoration.  I'm having a similar thing with my Westfield at the moment.  Where did you get the exhaust mounts from?  I recently got a couple from Westfield directly, but those ones look a lot more purposeful than mine do.

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Paul T

Had a fantastic day out at Stoneleigh yesterday, was a great feeling to show the car off and the nice comments received makes the cold winter hours in the garage feel worth while, met lots of nice people and saw some great cars, I loved the variety and sheer number of Westies all in one place!

 

Also picked up some bits for the car, thanks to @Rob5 for the new tunnel carpet and @Rory's Dad for the old dominators - which i’ll try my best to give a new lease of life, I also picked up a superb brolly from @Howsafe Workwear and Safety Equipment, the black on white logo looks great and the brolly itself has got to be the highest quality umbrella known to man😁...it’s properly solid! really pleased with my purchases, just need to find the time to fit the carpet this week and and strip the old lights back to see if they can be saved. Looking forward to next year’s show already 👍🏻

 

 

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