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Go Back   Madabout Kitcars Forum > Mad Build Area > Seven Style builds

Seven Style builds Westfields, Caterham, Dax Rush, Luego, Robin Hood, Tiger, Locust, MK, RAW, Quantum, you name it, you're building it, share it here.

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  #61  
Old 11th May 2023, 09:00
Mick O'Malley Mick O'Malley is offline
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There has been a brief hiatus in cave focused activity, as Mrs Blackbird has set up home there and is patiently sitting on her clutch. Even were it not illegal, I wouldn't disturb her.

Regards, Mick
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  #62  
Old 19th May 2023, 09:01
Mick O'Malley Mick O'Malley is offline
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Default Bye Bye Blackbird.

Sometime mid-week Mr Squirrel had eggs for breakfast, so the cave is now free again. Hurrah!

Yesterday I decided to bite the bullet and swap the differential for my 4.1. To improve access I turned the frame around and set to work in the sun. Starting on the off-side I removed the wheel, then the spacer, together with its pillar bolts. The drum only needed gentle tapping to come off, the shoes offered no resistance, so I now had access to the screws (three only in place!) securing the retaining plate. They were a little fiddly, being masked somewhat by the flange, but were soon off. I suspended the backplate with a loop of the ever-useful paracord as I didn't want to disturb any of the braking gubbins at this stage. I replaced the drum back to front as an impromptu slide hammer and the half shaft was out. Repeat for near side.



Pessimism dictated a drip tray in case any hypoy was left in the banjo, and I cushioned the cross member with a chunky fleece before sitting down to attack the retaining nuts (again, three only). The one at the top not having been bathed in oil dribbles was very rusty, as was the stud. Unfortunately, it was a Nyloc, one of my pet hates, so I could get neither a socket nor a ring spanner onto the meat of the hex due to the casting masking its bottom side. Aaaaaaargh!. An open-ender proved ineffectual, even after a blast with the blow lamp, so I gave up after giving it a good soaking with penetrating liquid. I shall resume with mole grips later today.

Regards, Mick
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  #63  
Old 20th May 2023, 11:49
Mick O'Malley Mick O'Malley is offline
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Other tasks taking precedence yesterday, I only returned to the cave this morning, brimming with enthusiasm and determination. I adjusted the mole grips until a mighty heave was required to lock them in place. Lamping the errant nut until the burning nylon and penetrating oil fumes half choked me, I applied gorilla strength to the grips. They rounded the nut even further. OK, re-think. Fetching my smallest cold chisel, and sharpening it on my bench grinder, I chopped off the cage containing the remains of the nylon and set to driving the remains anti-clockwise with lump hammer blows until the still hot nut yielded. Hurrah! I then wormed into position to release the three remaining at the bottom. These turned out to be barely finger tight . The copious gasket goo (no gasket!) offered little resistance and the drip tray proved its worth!



It then dawned on me that, although I had the new gasket, half inch AF nuts were sadly lacking, so it was back to the keyboard for their purchase and this update.

Regards, Mick
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  #64  
Old 27th May 2023, 07:43
Mick O'Malley Mick O'Malley is offline
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Default Dutton Nostalgia...

Thinking about next weekend's Kit Car Show, just up the road in Malvern, I thought I'd dig out some 80s memorabilia . My first show was in '87, by which time I was DOC magazine editor, and we had just shy of 100 cars on our stand! In those days one was issued a windscreen sticker (which poseurs like me kept in their Phaeton for a couple of weeks).



In the same happy memories box I found entry and camping tickets for Le Mans. The first couple at least were in my first Phaeton, subsequent ones in my matt black Dutton Sierra, dubbed 'The Stealth' by compatriots.



For the first few visits we camped at the sites within the circuit, then discovered Hunadieres behind the restaurant outside the circuit half way down the Mulsanne Straight (sadly by then ruined, IMO, by the addition of chicanes). At this site you just turned up, pitched your tent, and a guy came round with a book of tickets. A much nicer site altogether,



Happy Days!

Back to the build: I searched high and low for the diff gasket I'd bought at the same time as the 4.1, but without success so bought another which arrived yesterday. I now have all the necessary for this job, Monday it is! I'd decided a week or so ago to renew the half shaft bearings and bought same. An inquiry of the ever helpful Stroud and District Motor Club FB group for an engineering workshop who could fit them elicited a response, and later this morning I'm taking them there (ten miles or so) for the job to be done. The proprietor said he's very busy and wouldn't get around to it for a couple of weeks. Not a problem with plenty of other jobs to be addressed down in the scorching cave.

Regards, Mick
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  #65  
Old 27th May 2023, 11:41
Dpaz Dpaz is offline
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Great stuff, it's nice to read some chat on the forum. Especially about yesterdays.
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  #66  
Old 31st May 2023, 11:58
Mick O'Malley Mick O'Malley is offline
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Default More Dutton Nostalgia

Having suffered something of an enthusiasm bypass, the grey windy outlook, and spurred on by Dpaz's encouragement, I decided to delve into the memories box and post some more retro drivel .

These four relate to my first Phaeton. A neighbour just down the lane kindly lent me the use of his garage for the first two weeks of the build, during which I managed to clap on the suspension and steering, and drop in the petrol tank. It was then towed the 100 yards uphill to the village hall car park, handily opposite my gate, where I completed it over the next two and a half years at the end of a wander lead, mainly after dark. The multi-coloured bodywork was what Tim Dutton referred to as "Multi-coloured, suitable for spraying", this option resulting in the princely saving of 25 quid which paid for the 'B-Type bonnet and front wings' (i.e. Lotus Seven style) option.

Next is my dash layout which I hope to replicate on my current build. The DOC badge was designed by my good friend who was a close neighbour in those days, and something of a mentor as he was (is) DOC member no.9.

The third was taken at the Caen ferryport on arrival for the '88 Le Mans. Seems only one of us spurned sidescreens...

The last was on the way back from Le Mans in '91, the Phaeton now sporting Lotus themed colours and scrapyard front wheels, bought as I couldn't afford new rubber for the 5.5Js, having just had a third storey built on my cottages.



The four below are of the frame of an engineless B-Type I bought for a hundred quid in maybe '92? I'd already dismantled it when a Rover V8 engined project became available which I snapped up, passing on the B-Type (for what it had cost me) to the above mentioned friend. We motored over to Kent one Sunday in his Mk II Escort Ghia (which he later kindly loaned to me for a year when I was separated and penniless) where he bought a Lotus 2.2 litre slant four to put in the Dutton. 30+ years on they are both still lurking untouched in his shed. The B-Type's frame hasn't fallen apart because the joints are brazed rather than welded.



If only I had a scanner...

Regards, Mick
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  #67  
Old 1st June 2023, 09:21
Mick O'Malley Mick O'Malley is offline
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Default Dutton Drivel cont.

Quick photo' update. The top two are Le Mans '91 related, first one taken just before the off. My pal had just had a kidney transplant, freeing him from dialysis tyranny and facilitating trips out of more than one day. The second is on the Mulsanne Straight a couple of days later.

The bottom two demonstrate varied project delivery modes. The left hand one is the above mentioned B-Type loaded for delivery to my DOC friend's place over the valley. My 50 quid Subaru is parked in the very spot where I built my first Phaeton al fresco. The other photo' is of a newly collected Phaeton project towed by my Stealth Sierra using my Dutton towing gismo. The rig is outside my DOC friend's place where we stopped off for a coffee break. The Phaeton languished outside my digs until I flogged it and the Sierra having decided to go back exclusively to bikes. Happy Days!



Regards, Mick

Last edited by Mick O'Malley; 2nd June 2023 at 16:31.. Reason: Typo.
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  #68  
Old 5th June 2023, 08:08
Mick O'Malley Mick O'Malley is offline
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Default Quick Update.

Went to the show on Saturday, left at about 1300. Seriously underwhelmed. Bumped into Car Photographer and Lucky .

Yesterday I finally got around to fitting the 4.1 diff. in anticipation of today's trip to collect my half-shafts with their newly replaced bearings. I cut a piece of card to fill the hole in the banjo and carefully cleaned both the threads of the studs, with a wire brush, and the mating surface with acetone. I heaved the replacement diff. onto the bench and likewise cleaned the machined surface and passed a rag through the mounting holes. As advised by an internet search, I applied a smear of Loctite 574 to both sides of the gasket, slipping it carefully over the studs before hooking the diff over them with one 'safety first' nut on the top stud. My new split washers and plain nuts went on a treat. I couldn't find anything on the net regarding a torque setting for them so used a common sense amount gauged by wrist.



Excuse rubbish photo'. As soon as 'school o'clock' is over, I'll hit the road for half-shaft collection.

Regards, Mick
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  #69  
Old 6th June 2023, 13:17
Mick O'Malley Mick O'Malley is offline
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Default Back Axle Progress.

Scratching around the various back axle bits and pieces the other day to see what was required, I was delighted to find a pair of new wheel cylinders, for which I ordered a fitting kit and rubbers. I also bought a small bag of 5/16-24 x3/4" set screws so that the half-shaft retaining plates could have their full complement. All the brake shoe fittings are present, the shoes themselves have plenty of meat, so I turned my attention to the backplates and drums. After a good wire brushing the former looked serviceable (although one had a couple of 8mm looking holes drilled in it, presumably to facilitate blacksmith style drum removal). The latter came up OK, except for the friction surfaces. One was grooved by previous shoes' rivets and the other had some pitting.



All three of my previously used light engineering workshops having closed, I searched on line finding another only a couple of miles away which looked hopeful. I whizzed over there this morning where the somewhat surly receptionist said "I'll find someone for you." The bloke who came to look at the drums asked what they were from: it turned out he's a kit enthusiast and pilots a turbocharged Pinto engined Robin Hood 2B. We chatted kit cars for a few minutes - he'd been to the show - then said "Come back tomorrow", hinting that he might be able to skim them as a 'foreigner'. Serendipity!

Hopefully I might actually be able to soon start some re-assembly .

Regards, Mick

Last edited by Mick O'Malley; 6th June 2023 at 13:18.. Reason: Smiley.
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  #70  
Old 6th June 2023, 21:35
Dpaz Dpaz is offline
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Finding light engineering places is getting very difficult. I needed a couple of spacers modified for my S1 Landrover. The only place I could find charged me a small fortune which was the economic price. not a few quid for a foreigner! Mind you there don't seem to be many people doing our sort of modifications, more sctap it and buy new.
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  #71  
Old 6th June 2023, 22:11
Lucky@LeMans Lucky@LeMans is offline
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I've been lucky in my line of work from full engineering workshops to as little as a lathe in a corner with next to no tooling ! Currently I'm at a place that is the latter but the company have promised me this and that in the coming months and a milling machine, heaven !
There are places out there, along with laser cutters. welder fabricators etc but few are cheap or willing to do bits on the side. If you find one keep them sweet, bear, booze and cash can do wonders and they won't mind you going back !
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  #72  
Old 8th June 2023, 08:39
Mick O'Malley Mick O'Malley is offline
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Default One step forward, two steps back...

Yesterday morning, armed with some folding money, I went to collect my brake drums from the above mentioned Good Samaritan. True to his word he brought them out, freshly machined. When I asked him "What's the damage?" he replied "Nothing, always glad to help someone out". Amazing! Earlier I'd Fertan'd my back plates so I was ready to start re-assembly. Woo Hoo!



I popped a back plate over a half shaft, and slipped the latter into the axle, only to find that the bearing was slightly too deep. Aaaaaagh! Being a trusting soul, I'd taken the Ebay vendor's description that they were correct for this application. So, I now have to go round the block again .

I've bought the correct set after VERY careful scrutiny of both the vendor's feedback comments and item photo's/description. Fingers crossed I'll be refunded and end up only the twenty quid I paid for having them pressed on out of pocket.

It's no fun if it's easy. Yeah, right.

Regards, Mick
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  #73  
Old 8th June 2023, 20:15
Lucky@LeMans Lucky@LeMans is offline
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Depending on how far out they are could you fit an alternative bearing or get a spacer made up ?
Sounds like you have found an old school engineering shop, I'd give them something as thanks if you go back again !
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  #74  
Old 9th June 2023, 08:44
Mick O'Malley Mick O'Malley is offline
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Quote:
Originally Posted by Lucky@LeMans View Post
Depending on how far out they are could you fit an alternative bearing or get a spacer made up ?
Sounds like you have found an old school engineering shop, I'd give them something as thanks if you go back again !
When I collected the half-shafts there was a young (well, to me ) lad only there. He said they were basically a garage: their only two machines were an hydraulic press and spring compressor. I looked at the brake drum establishment's web site and they have the lot! In their tiny reception area there were quite a few amazing CNC machined exhibits to admire.

The bearing is too fat, so when it's home against its register the retaining plate is clear of the axle's flange.

When the correct bearings arrive, as well as the half-shafts, I'll take my ally hubs with me for their bearing races to be pressed in - I don't fancy risking the 'socket and lump hammer' method. Yesterday I examined the existing front hubs and decided to remove the PCD adapters in case they were of use to anyone. Answer = No! I think they were not only machined from a neutron star but had stripped attachment threads.

Regards, Mick
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  #75  
Old 5th July 2023, 09:07
Mick O'Malley Mick O'Malley is offline
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Default Quick update :)

My works pension arrived on Friday, and Saturday was my birthday (75th, ouch!), so I treated myself to some more shiny bits for the front end.



The nice man delivered them to my neighbour yesterday, and I collected them this morning. Calipers (Type 14); pads & fitting kit; hoses; and discs. I'm now waiting for the 'phone to ring to let me know that my half shafts have their correct (Consul Classic 315!) bearings pressed on, and likewise the outer taper races into my ally 108mm PCD adapter hubs.

Regards, Mick
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  #76  
Old 6th July 2023, 10:28
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Happy Birthday, Mick
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  #77  
Old 6th July 2023, 22:29
Dpaz Dpaz is offline
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Very soon you will wonder when you had time to go to work! Welcome to the club!!
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  #78  
Old 12th July 2023, 20:42
Mick O'Malley Mick O'Malley is offline
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Unhappy Jinxed? You bet!

On Monday, the guy pressing in my bearings rang to say that the half shafts were ready, but that there was a problem with the hubs which I needed to see. Today I pootled over there and examined the problem. These ally hubs came from Merlin Motorsport, a thoroughly professional outfit based at Castle Combe which I have used a good few times. It seems that whoever programmed the CNC for this batch of hubs made a boo boo and machined some inserts in an attempt to correct their error. Sadly, these are too thick and simply began to crush under the press attempting to push the bearing race into a too small recess.



My guy was extremely apologetic, as he takes pride in his work and was clearly gutted to have to disappoint a customer, even offering to contribute to the necessary remedial work. We discussed it and agreed that I should take the offending item to Maynard Ltd (an absolutely top notch specialist engine machining establishment of almost 40 years' standing), not far away, for an opinion. There, the ever helpful staff pulled up Merlin's spec sheet on line, and using vernier calipers confirmed that it was indeed the manufacturer's error. Whilst I was there, the proprietor, who is THE Imp (and hence Talbot Sunbeam 930) guru, talked me through what goodies I would need to get the sort of sprightly road performance I would like. The piggy bank is going to take a hammering!

So, tomorrow I'm off to the offending emporium with the errant items to seek their proposals for remedying the situation. Favourite for me would be replacement!

Regards, Mick

p.s Thanks for birthday wishes .

Last edited by Mick O'Malley; 12th July 2023 at 20:46.. Reason: Punctuation.
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  #79  
Old 12th July 2023, 21:06
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That's very disappointing, hopefully Merlin will do the right thing for you.
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  #80  
Old 13th July 2023, 19:59
Lucky@LeMans Lucky@LeMans is offline
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Merlin are very good on the whole, used them a lot over the years.
Take them back and ask for their opinion. Might be worth giving them a call before hand and tell them you are doing a 100 mile round trip to see them specially !
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