Clearing out the boot

Thought id make a start on the interior a bit. It needed a lick of paint. First of all I had to clear out the rubbish id left in the back. An old battery charger, some old bits of wire, some oily racks to mention a few bits.

But I did find a brand new OE oil filter and these 2 bits which I was very pleased to find.

The missing towing eye cover!!!!! These are pretty rare as nearly 99% of Renault 5`s I see have them missing. And also a brand new door catch which I desperately need as my sagging doors have shredded mine!

I also found a new braided oil feed hose for the turbo. Sods law really, as id already bought another one as I couldnt find the one I bought years back. Still, its handy to have a spare, or I can always sell it on.

Result!!!!

New dials/gauges.

I had a bit of spare time in my lunch hour today, so I decided to make a start on the dials. As you can see in the picture above, id fitted a white dial kit many many years back and it had long since faded into orange. So I bought a new set of lockwood white dials and fitted them. Its a pretty easy job if you take your time over it. The clear perspex front is held on by 4 clips top & 4 clips at the bottom, pop them off and you can get to the dials as above. The speedo & the rev counter have 2 small screws holding the face in. The other 3 gauges use small rivets. The needles can be levered off using a fork from the kitchen! But, make sure you note the position of the needles before you pop them off.

As you can see, the improvement with the finished result is much better. Above is a spare set of OE gauges I have. I swapped some of the needles over as mine were a bit more faded, but you can see in the pic above just how faded the OE dials get. You can get a replica set of OE dials from the RTOC website. They are made by lockwood who made my white dials above.

Pic below of the finished item fitted back in the car. I just need to screw it down at the top. You can also see the OMEX shift lights. Im going to glue that to the underside of the sun shield top part of the speedo housing. It should look fine there.

Rear bumper. Rear brakes & fuel tank strap.

I decided to make a start on the rear bumper this weekend. You can see the state of the mounts here! The bumper is held on my 1 bolt each side under the rear wheel arch of the car and one at the back. The top mounts were so rotten that after undoing the bottom bolts, i could just simply pull the entire back bumper off the car with a bit of force!!

 The other side was just as bad as you can see here!!!!

 I cut out the old metal back to solid metal and treated all the rust with some rust-to-good-metal chemical stuff. Then welded in some new sheet metal. I then seam sealed it and painted it with industrial black paint. I will have to drill new bolt holes in it to mount the bumper back on once ive finished.

Whilst I was under the car I thought id have a look at the reserve tank strap. This is notorious for rotting through and falling off. As you can see in the LH picture, mine also has fell off at some point. A new strap is £45 online. Looking at the actual metal i realised i only needed a bit of steel, 3 or 4 cm wide and about 40cm long. Looking about the garage I found a suitable bit of metal in my scrap pile. I just chopped the right length off and welded it straight onto the old metal. (after chopping off the rotten bit). It easily bent around the tank to shape and after a lick of paint looked brand new.!

The funny thing about this is that after finishing it was puzzling me as to what the scrap bit of metal actually came off, as it looked perfect for the job. After a bit of head scratching I realised it was actually the fuel tank strap from a classic Mini Cooper which id scrapped many years back. Looking on ebay these sell for £28! Doh! So I didnt save quite as much money as I expected in the end!

I had a bit of spare time so I wired up the launch control button . I fabricated a small bracket and bolted that to one of the steering wheel to boss bolts, and positioned the button so its in perfect reach of my thumb whilst im gripping the wheel. Im pretty pleased with how it came out as you can see in the picture below.

A couple of other bits I needed to do was to finish the drivers side rear brakes. Id already fitted new discs, pads, callipers, braided hoses & new brake lines to the passenger rear side, so it was just a simple case of doing the same to the drivers rear side. They all just bolt straight on, nice & easy. The only hassle I had was the brake hose->line brackets, the RH side ones were completely rotten away so I had to fabricate some new ones - easy as you can see below!

And heres the finished result... completely new brakes at the back! Not looking forward to bleeding new fluid through this lot though as theres a lot of joints to check for leaks!

Exhaust & handbrake. Plus a start on the RH side.

I was hoping to get a good day in on the car this week, but other things have come up and ive also not been feeling too great, so havent managed to put much time in. I was up at 5am again today, so after feeding the baby and cats I managed to get in the garage for 7am.

First thing I managed to do was to remove the exhaust. I was running an after market Scorpian stainless system which I think is about a 2inch bore. This system comes in 3 parts so is easy to remove. The downpipe is bolted onto the rest of the system using 13mm bolts and springs. Easily got to from underneath the car. Im replacing this with a 2.5inch side exit system. You can see the difference here in the 2 pictures below. The new system looks like its been thieved from a lorry or something, it looks huge in comparison!!!

Apparently the 2.5inch system is good for 250bhp so it should last me a while. Very annoyingly I missed out on a tubular exhaust manifold today on ebay. It went for just 80quid and I was prepared to pay upto £100 for it. Oh well, i will keep my eye out for another one.

With the downpipe removed you can see behind the engine nicely. And see the starter motor. Ive changed this before, many many years ago, and normally the best way to get to this is under the drivers wheel arch. Ive a high power one to replace this one, so thats another job on the list, but will have to wait until I can get under the drivers arch - still with the downpipe out, access will be much easier.

After removing the exhaust I was looking to see what next I could do. Finishing off fitting the new LH handbrake cable was a good start. Under the car you can see the handbrake adjuster below. Theres a 13mm lock nut, then a 11mm nut and a knurled adjuster. I was expecting these to be completely seized, but to my surprise they werent. I did notice they were on max adjustment though. So I slacked these off completely which allowed me to remove the old handbrake cables from the pivot bit. I lubed this up with plenty of copper grease and cleaned it all up. You can see in the 2nd pic the new handbrake cables fitted. I will adjust the handbrake up after ive finished with the rear brakes.

Whilst under the car with the exhaust removed you can see the brake lines & fuel lines going from the back of the car to the front.. you can see they look a bit rusty. Im going to replace these.

So I then decided to make a start on the drivers side of the car. I pulled the car away from the wall a good bit and jacked it up on axle stands. I was hoping the drivers side was better than the passengers side, but unfortunately not. Jacking point at the front is shot, and mega rust along the sills. The back bumper mount below left is completely rotted away. So looks like I need to buy some more steel sheets to weld in!

Also under that side you can see the fuel pump & filter. Im pretty sure this probably the original fuel filter! Ive a high capacity fuel filter and a more powerful fuel pump to fit here. Ive sprayed all bolts/clips with penetrating oil so hopefully they will come undone easier.

Whilst i had access to the drivers rear side of the car I stripped off the rear brakes. Only took a few minutes. The bits are below. As with passengers side, ive new disc, caliper, pads, lines & hoses to fit here. I did feed the new handbrake cable through the rear trailing arm so thats all ready and did make a start at trying to remove the original brake lines this side. They are proving hard as the reserve fuel tank is in the way which is messing up access to the lower brake line. The top one came off easily enough after cutting the line off and using a 11mm spanner on it. Anyway, thats it for today, a good 2 hours work. Hopefully will be able to put some proper hours in next week.