GRIZZ’s English 2001 S10 Extra Cab 4.3 V6 Truck

[Liz]

Originally Posted by Grizz1963

One of my American buddies is building a house for a lady friend……..

I am always amazed at what people get up to.

Andy is beyond 70 and very successfully retired from the Oklahoma oilfields.

I guess some people need to keep busy.

I asked him for a pic that included him.




Wonder what I will be like in 15 years.

God bless him. I only hope I have that energy at 70

[Palf70Step]

[Grizz1963]

Originally Posted by Palf70Step

Boooom.






Back home and out by 11.00 today.

Breakfast was nice, but felt like a waste of garage time.

Still, no regrets.

So I tidied up, and added a few bits to the welds.

Also opened the mounting holes on the tabs.



And on so that I could work out the next job…….

Guessing time.

What?





Once the tank is fitted the filler neck is now this low as I have dropped the tank so the MX5 fuel system can fit under the floor.



So I created a template to cut away the bottom of the toolbox that will hold the filler cap once completed.

Cut, cleaned up.



Ready for etch primer.



And primed.



I think it will be a Marmite addition to the car.

I like Marmite.

[Grizz1963]

For those who like animals, and in this case, dogs.

Went for a walk, met a German Shepherd named Gus. Adult dog.

She went straight in and was running circles around him.

Back home, typically, she figured out she could get into the bird bath for a drink.





Water dog?



Certainly worth the money the Parvovirus cost us.

Every day is a joy.

[Grizz1963]

Paging @nickwheeler

Hammerite rules.

One for you

Painted tank.



Also test fitted this one.

I know there is a change I am considering but need to consider it first.





Back in a bit.

[Grizz1963]

RIGHT………


Time for the Tech-Heads to pop their heads up like a family of Meerkats.


Exhaust and Tank were the last big jobs to get done before bolting the body down again (maybe finally)

Along with brakes, wiring etc that are all easier to get to without the tub in the way.


So on Sunday after bolting the tank into place, this was the view from the rear.



And poking a long stick in the open down pipe and resting it on the rear axle gave me this……



I could not get the Ford Ka 1.6 rear box that @kevins donated to the build, in there with it curly piece attached. And was not going to start cutting it up.

Measuring up the various length and diameters gave me this…….

Ford Ka rear box entry is 2” but the pipe welded to it is 1.75”

It will need cutting and rewelding to make it over the rear axle, fit next to the tank and hang in a way that the rear exit pipes look right.





On the engine side the original down pipe exits this flange at 2” vs the rear end at 1.75” of the Ka bendy bit.

I am happy to reuse the Ka bendy bit of course, if I can make it all come together.

Having spoken to @pauly my guru (one of many) it seems that change in diameter will make little difference in this sort of car.





So it leaves me with about 1200mm of straight 2” pipe to buy and some fiddling to make it all come together, and some welding,and a clamp or such, along the way.

Paperwork summary



Over to the collective.

[Palf70Step]

I think I would try a sawsall and cut the bolt. The take a cutoff wheel to get that not out of the way

[Grizz1963]

Originally Posted by Palf70Step

I think I would try a sawsall and cut the bolt. The take a cutoff wheel to get that not out of the way

Spot on Bill.

[Grizz1963]

Before I forget.

Ordered some Johnsons Klear off Amazon to coat the badges with.

Said to dry both hard and with UV protection.

Also did the black outlines.

Plenty Good Enough for a 3 foot inspection.





A lot of the detail will be lost on the casual observer.

But it makes me smile.

[Grizz1963]

Using my special, banned tool, I got the second nut undone.

The threads are good, and new gasket was ordered, will get some new nuts.

Job done.

[Grizz1963]

Went to Euro Car Parts yesterday to collect a Nissan Micra high pressure fuel filter @pauly made some suggestions for me to consider that includes a return valve that may be needed in the system.
Hopefully @nickwheeler can decipher Pauls advice.



While out, I saw a nice example of some French engineering that with small, subtle tweaks, drew my eye.



I had ordered two 57mm exhaust clamps and a gasket, along with the fuel filter.

Looking at the list pricing, I wonder how these prices differ so wildly.



When I collected, they only had one clamp.

Slightly miffed, I was sure there would be another at home, but it is a risk to hope you have a random one floating about.

Serendipity.

Got home and the straight pipe I had ordered was delivered on time, by DHL.

Guess what…..?

An exhaust clamp included in the price, I had not realised.

John my one lodger was home early, and took a pic when I laid them out.



Job for the weekend.

Next job was to quickly assemble the tank inners.

Pump, return etc.

Got the original screws and realised that the build was done using M5 nuts rather than the M3 that was standard on the MX5 tank.

Thankfully I have a tub of nuts, bolts etc in all sorts of sizes that always gives and gives.

Got 12 bolts and tried them, 5 of the nuts would not thread in, so out came the small Tap and Die set and a quick run through saw me fighting the next fight, threading them all and keeping the rubber gasket in position.



Fuel pump arm shortened by 60mm to fit in the new custom tank.



Pray this lot does not need to be taken apart again.



Also looked in my collection of three filler caps to see if one fitted……..

Nope.

So need to go out and find one

I suspect that this is a former Ford filler neck.



Hopefully not too hard to find one.

[Palf70Step]

Looking good Rian. I think it would be REALLY good with those great big meats in the rear. Keep on roll'n bud!

[Grizz1963]

Originally Posted by Palf70Step

Looking good Rian. I think it would be REALLY good with those great big meats in the rear. Keep on roll'n bud!

Thanks Bill.

Little bit more every day.



Badges.

Remember them.

Covered in floor polish, crazy? Seems not.







Last night I also added the second layer of scrim foam.



Tonight I cut it back and then trimmed the edges.

Next stop will be the black vinyl.

Fingers crossed.



Also yesterday, I went to JWE engineering to see about having a Custom propshaft made up.

Mazda one side, Ford on the other.

Around £200.00 and I supply the MX5 propshaft to have a Ford back end added on.



So I measured it and delivered ‘them today.



Turn around time could be 2-3 days

.the differential flange uses bolts, screwed into it.

Weird size that I cannot readily buy off the shelf is a collared, M10 x 1 and 18mm long bolt.

So need to get four of these high tensile bolts.



I continue to be amazed by some vendors on Ebay.

On Monday evening I ordered this silencer.

Delivered before midday today.

Service.

Compared to the unit @kevins gave me, this is a bit shorter and smaller.

Just hope it all fits neatly.





Last bit of delivery pleasure today was the stick on number plate to go on the rear.



This will fit in above the fuel filler toolbox and next to the rear lights.

.

[Palf70Step]

Like the black wzybetter than the Shiney. Good work crew.

[Grizz1963]

Originally Posted by Palf70Step

Like the black wzybetter than the Shiney. Good work crew.

Morning mate

Yes, the black is 100% better.

The shiny was free, but that did not make it right, unfortunately.

The whole black underside theme looks uniform.






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And it is Monday again.


Another day of stuff getting done.

I removed the self destruct button from the rear that fascinated a few people.

Suspect it was an alarm switch attached to the monitoring of the original rear mounted spare wheel.

Filled all the holes on the rear too with a fiber resin mix.



Nick got going on threading the rear wiring, and managed to get them the wrong way round, soon fixed by removing and refitting correctly.



Some of the lines are not yet live due in part to his over eager stripping back of the loom.

But should get a fix next weekend.



Due to the situation of the MX5 fuel tank, directly behind the drivers seat, we were concerned that this loom may need extending by 150-300mm

Glad to report that a big Whooooop ! From under the car signified the moment Nick got that wired in without the need for extending.

This is a big win and having everything fit safe and loosely under the rear floor was always planned, hence me dropping the tank lower by 50mm when I added the tabs.




During the day I removed the lifting straps, cleared out some of the materials in the carport and did a bunch of little odd jobs that need doing.

Looks tidy and like a real car under there now.

Glare does not allow a decent picture to be taken.



Also did final fit for the fuel filler toolbox and bolted that down.

And mocked up the license plate.

Happy with that.



Still a ton of small jobs to get done like adding fiberglass and resin to the floor for reinforcement

Final fitting of the seats once they go back in.

Lights, dash upholstery and other panels, plus a final decision on heater blower vents and pipework.

And then some more bits.

Have a good week.

[Grizz1963]

One of Sundays jobs was reconnecting the hndbrake.

And yes, it works, engages rear wheel drums, but…… the handbrake will not engage a ratchet.

The handle lifts, the button is locked in place.

Any ideas?





So that did not work too well.

Advice?

Anyone for a handbrake lever stashed somewhere?

Thanks.

[Grizz1963]

Remember the blower/heater unit built and fitted a while ago?

I need to finalise and button that up.

Went to the scrapyard yesterday and did not find the ideal donor, but a corrugated vacuum cleaner pipe could just work.

Also found these two damaged, but neat toys (ornaments) for sale at £5.00 each.

And when I got home I pushed the car out into the sunlight for a better pic of the rear end.

Not perfect, but better.







.

[Palf70Step]

Good work. Glad it all came together.

[Grizz1963]

Originally Posted by Palf70Step

Good work. Glad it all came together.

You can get a new one on Ebay, but £249.00 or near $340.00 is too much.

And even used if you could find it……. Naaaaahhhh.

[Grizz1963]

So while Nick cut, measured, cut, ground and made up the last part for the rebuilt handbrake lever and fittings, I carried on with a job that had been spinning around in my head for some time now.

How to balance the number plate, light and toolbox to the left which left a large vacant space on the right.

I always wanted the car to have a 4x100 space saver spare wheel and a simple brace and jack.

Planning was to just bolt the wheel in the rear boot of the car.

Simple really.

But if you recall, the car came with a spare wheel carrier, long since removed.

So while Nick fabricated, I searched, and then started to fabricate as well.

Space saver and carrier. Studs were 4x108

Ooooopps, too big a gap.



Unless you managed to move the studs closer to each other.

And remove years worth of rust from the threads.



Is this close enough?

Moved the studs closer didn’t I?



Next job………

Tack and stick weld for deep penetration.

Then copy three holes over to the rear tailgate, drill holes and test fit.



Backing plates cut from horrible checker plate.



Not yet fitted, but you get the idea.



Bracket and wheel nuts painted Satin black, Nick and John were super excited watching my work become ever more beautiful.



I masked up the space saver after giving it a good ScotchBrite scour, clean-up

Black centre and the mustard/sand outer rim should look like the wheels fitted to the car. Well, sort of.



And result.

Could possibly paint the rim gold if it looks like it needs it.

Rear was painted all black too.




And while I was working on the spare wheel, which is really just to get me out of trouble, Nick fitted the brake reservoir that @glenanderson had sent earlier in the week.



I must say, I am really pleased with the jobs done today.

More progress made.

.

[Grizz1963]

After another rubbish night, I was woken by the cat I do not own.

After feeding him, he went out to sit and watch is property.



So this morning I fitted the newly welded and painted spare wheel carrier.

No plan to add an alarm switch to the spare, so deleted that.



Masked up the space saver that I had painted black last night after deflating it, tucking the cardboard under the rubber.

Ready for paint.



Once the paint partially dried, I removed the cardboard barrier.

Happy with that.

Tidier than it was 24 hrs ago.



Once spare was fitted to the carrier I fetched the old license plate and the new one.

Ugleee vs pretty.



Then pushed the car out into the sunlight.

Really happy with the look, except the roofrack, or is it roll bar?



Next job was to start on the side panels in the dash to start figuring where to exit the two footwell vents.

Dash back in.

Ohhh, and I redid the scrim foam on the screwed up kick panel.



Marked and made the first hole.



Also made a pair of super ugly joiners for the blower to get to the vent holes.



The back ends will be bonded straight onto the sides of the blower unit.

[Grizz1963]

First bootfair of the year.

Two hours out and back.

Back to yesterday.

While I worked on the heater blower and dash panels, Nick continued with the rear wiring and lights.

Found this unholy mess………



Resulting in 6 hours work to get right, to be tested later today.

And as always, nothing is easy.

He ended up having to cut the mounting bracket bolts as the rivnuts just spun around, and the space up the rear of the body is very limited.

Leading to this.



Much grinding, fabricating and time wasted fixing a previous builders mess us, we got to this point.

Mazda MX5 loom spliced into Ford parts.



And back in the body.

Threaded rod still to be JB Welded in place to hold brackets.



Wash, rinse, repeat on the other side.

Waterproof Connectors were a bit of a “bargain” at £16.00 for the box.




After much planning, measuring, I made up the “ducting” for the blower unit to hopefully connect with the director nozzles.

Then started to attack the actual blower unit box that was made up weeks ago.

I do love a step drill.



Too late for tears.



Possibly the most useful and underrated tool in this whole build.

Powerfile rocks.

Get one.



And ready for the ducting and base plate to be glued on.

Hope it all comes together.




Saw this on FB this morning.

A hot MX5 under there.




What shall we build next then?

[CG]

You're going to have this thing ready to enjoy a beautiful hot British summer. Enjoying your build, ingenuity, and sense of humor.

[Grizz1963]

Originally Posted by CG

You're going to have this thing ready to enjoy a beautiful hot British summer. Enjoying your build, ingenuity, and sense of humor.

Thank you very much CG.

I appreciate you taking time to post up a reply.

There are obviously people looking in, as the post count keeps changing.

And yes, being patient and a sense of humour helps.

This car fights you every step of the way.


It was summarised well be a chap on RetroRides



The progress on the Rocket is outstanding.

I check in every couple of days and there are usually two pages added to the thread, shows how popular it is!

was thinking that you're building a kit car, but instead of starting from scratch with a big Airfix kit and a base car, you're using one that someone else started decades ago, left to rust for years, then restarted by yourself (& Nick) using a different base car and no instructions, very difficult indeed, hats off to you both for the speed with which the car is moving forward.














Been thinking inside the box again.


The plan all along was to fit an inline tap or control valve in the heater hose from the engine.


BUT…….


Then I started wondering, would it really make any difference if the coolant just circulated through the heater matrix permanently

And if one used the blower to push air through it onto your feet only when you wanted hot air to circulate there.

That way, you never interfere with the circulating volume or thermostat where it passes by.

Do keep in mind, this is a good weather, open topped, and essentially no doors, car.

[Grizz1963]

Loads if day job stuff done, customers, emails, calls etc.

Managed to pull some mangled shrubs out and cut the front hedge for the first time this year.



Late afternoon I went down to the garage after some water feature cleaning and repairs.

Started and completed the small side panels.



One done.

Happy.



And a pair of them done.



Sneaky photography.

Enough.

Weekend ahead.