Ready for the Road

STAGE 5 - FINAL WORK (91 hours)



30th May Used mains pump to suck petrol from tank. Reconnected pipes. Started with 'splurts' (improved later).

Adjusted clutch and tickover.

On braking and turning tyres touched wings. Raised suspension five turns. A bit better. Repositioned wings.

Glued wooden bits on to grille surround - to screw later.

31st May Screwed grille to wood blocks - one needs reducing.

Tried to re-fit front bonnet locks - needs more work.

Put VIN and LOMAX plates on.

Fitted, mirrors, licence holder and aeroscreens.

1st Jun Took by trailer and Dave Lowe's 4x4 to DVLA to be registered.
2nd Jun Re-adjusted and strengthened wings - thicker gauge metal support and cross member.

Put petrol in - overflowed - pipe needs raising.

Also gauge not reading right.

3rd Jun Raised petrol pipe using 3 cable ties.

Adjusted fuel sender float. Filled petrol tank more. Gauge better.

Refitted bonnet stay in new position (top of vertical support strut).

Approx. 454 hours so far.

5th Jun Made guides for front top bonnet.

Lubricated speedo cable.

Moved choke to left - used same hole as speedo. (Light needs re-connecting).

Put heat resistant strip on underside of bonnet - need some more for offside.

Put loom covering on nearside.

Adjusted/altered low front bonnet locks - still needs work on nearside.

Bled brakes.

6th Jun Completed loom coverings except for rear offside - can't reach. Fixed with self sticky aluminium clips.

Tightened handbrake cables (each wheel immovable [jacked up] on 7th position).

Adjusted/altered low front bonnet locks.

Moved choke back and in new holes to clear gear-lever.

Strengthened left side of dashboard with two metal strips from scuttle frame to fixing on back of speedo.

Fitted leather-cloth cover on Velcro over gear-lever scuttle hole.

Made and fitted GRP cover for fuel sender unit.

Noticed rear side lights not working (but brake-lights did) - found loose connection under steering wheel - fixed.

Adjusted choke tick-over screw - running very well now.

Checked heat of bonnet - seems OK.

On braking forward, noticed a noise - same as when applying handbrake on the move?

Got rear sidelights to work.

7th Jun Fitted new sparking plugs.

Bled brakes again.

Checked alternator output on voltmeter - rises as increase revs.

Filled holes (seatbelt rods, seat, old clutch, old speedo, old battery isolator cover, dzus clips etc.

Fitted leathercloth/Velcro over handbrake lever.

Removed grille. Reduced wood block for grille. - found that 4 blocks had come loose - probably because alternator pulley touched grille on braking - need to reduce depth of grille GRP at top. Re-glued blocks of wood.

Built up offside wing to bonnet level - more needed.

Put rubber covers on pedals.

Straightened instruments.

8th Jun Cut off excess filler, filled up where insufficient.

Reduced depth of grille surround top half by 3mm and replaced grille - noise on braking now gone.

Built up offside wing to bonnet level with more depth.

Levelled/filled holes.

Tidied up wires under dashboard.

Tightened exhaust end point - it was rattling.

Sanded down, rough and fine and T cut and polished wing blemishes and painted where cracks, new filler bits and alternator pulley yellow.

Sanded down swage line from back nearside to front cockpit (needs finishing, fine sanding, T cut and polish).

13th Jun Registration permission given at last.

MOT passed.

Problem with starting when hot.

Changed seat arrangement - nuts both sides of floor - needs large washer.

Adjusted plug gap- to improve starting when hot.

14th Jun Insurance from Footman James.

Picked up tax disc.

Changed seat arrangement - large washer.

Strip of wood between steering column and support.

Re-fixed grille - cut back and stuck new wooden bits.

Fixed front number plate (plastic bolts).

15th Jun Fitted new plugs (Equem).

Reversed front flashers (upside/down).

Adjusted height of front locks - tighter.

Removed bonnet. Screwed grille on - OK after trips - no rubbing from engine. Replaced bonnet.

Took out spacer from offside seat belt reel - to stop locking - seems OK.

After trips, noticed a little oil under crankshaft/union area. Tightened union.

Grease on bulkhead - from gaiters?

Still rubbing when suspension + corners - needs inch higher.

Brakes need bleeding.

16th Jun Bled brakes again - starting with front) - no better.

Fitted rear number plate (double sided sticky tape).

Raised suspension to 180mm - very slight rubbing in extreme cases.

Fitted new points and condenser -adjusted timing by rotating box clockwise 1mm in right hole.

Bent fuel sender to read more accurately.

Tightened gaiter cable ties to prevent grease throw.

Re-routed horn cable - fouling shaft.

Serious oil leak - squirting from offside - discovered leaky shoulder/gaiter connection on offside flexible oil pipe.

19th Jun Cleaned up oil from engine and body.

Replaced offside flexible oil pipe.

Corrected ignition timing with light.

Fitted new metal strip and new holes to bring handbrake closer.

Tightened and greased gear linkage.

Put clip on hose between oil filler and carb to correct kink. Clip to secure HT cable to choke cable - to avoid touching new handbrake extension.

Put speedo right - altered dashboards supports.

Adjusted throttle cable and carb tickover/choke speed screw.

Went well, though still a problem starting when hot - try mixture change?

Oil escaping from oil filler cap - cleaned up and removed large washer and tightened using plastic washer and nut not wing nut; cloth round to check.

20th Jun Replaced leaking master cylinder with one from scrap 1989 2CV.

Bled brakes OK.

22nd Jun Worked on swage line on bonnet front.
23rd Jun Continued working on swage line on bonnet front.

Tried raising nearside wing - no good but in towards centre ½ inch to avoid scuffing - little better.

Fitted adjustable throttle bolt above pedal.

Altered float (lifted up slightly).

24th Jun Other (nearside) flexible oil pipe leaking at bend.
26th Jun Fixed replacement nearside flexible oil pipe - OK.

Raised suspension 5 half turns offside 7 nearside - gap above tyre greater on offside but ground clearance greater on nearside!

Got replacement carb base and oil filler gaskets.

27th Jun Fiddled with mixture - made worse - blowbacks worse.
28th Jun Removed alternator, oil filler and carb connections to remove carb NB Nuts holding carb were loose.

Exchanged idle mixture jet.

Baseplate OK - added paper gaskets and washers (none before), new oil filler gasket.

Would not start. Offside cylinder fired sometimes (nearside exhaust cold). Points too wide - reduced - engine started.

Discovered rubber pipe from dipstick to oil filler torn.

28th Jun Replaced aeroscreen screws with smaller SS ones to look neater.

Replaced soft rubber pipe from dipstick to oil filler pipe with plastic version.

Moved choke to middle to avoid overtension in cable.

Made extension cap for idle speed screw.

Engine worked very well - no popping, but uneven tickover - probably needs mixture adjustment. Started fine when hot.

29th Jun Heightened nearside wing by making adjustable groove between 2 existing holes at bottom of box support.

Raised nearside bonnet lock, heightened offside lock.

Plastic insert in top of nearside box support to keep bonnet close to clip.

Leathercloth 'oil seal' inside oil filler lid.

3rd Jul Fitted oil drip tray from aluminium oven drip tray - made and painted bracket for it.

Raised rear nearside by half inch (5 half turns).

Made alternative tickover adjustment screw (wing nut).

Adjusted choke and slow running tickover.

Removed entry support handle - no real help.

Car running sweetly - tickover 1000 rpm - can use choke for idling speed adjustment.

Bent throttle pedal to enable toe/heel operation.

4th Jul Replaced broken bonnet lock with 2 new ones - longer stems - readjusted.

More rubbing down swage line on offside.

5th Jul More rubbing down swage line on offside and miscellaneous places.

Applied 'go faster' stripes.

Made box for gearlever tunnel.

6th Jul Finished gear lever tunnel.
7th Jul Leak from plastic oil breather - replaced with rubber + jubilee clips.
7th Jul Seatbelt rollers made vertical with wood insert - better.
10th Jul Adjusted petrol sender float higher.

Altered central mirror to focus lower.

11th Jul Made transparent hinged box for parking meter tickets etc.

Made bracket and was given U bolt from Lomax for seat belt middle height reducer.

Also given Lomax badge - fitted using silicon filler.

Tightened body/chassis bolts - front axle rear bolts quite loose - had not been peened!

Painted seat belt centre plate and fuel sender cover.

TOTAL TIME SPENT SO FAR: 537 hours

Watch the transformation from 2 CV to 223 in 5 'easy' stages

Click on each stage to watch it develop!

Scrap Happy Nut's'Bolts The Body Beautiful Fitting it out Ready for the Road Home