GRIZZ’s English 2001 S10 Extra Cab 4.3 V6 Truck

[Grizz1963]

Today was a great day.

Little to show, loads done and achieved.

Fabrication and planning.

I got out my pneumatic die grinder and tungsten carbide bits to get the hole roughed out.





And bolted to the firewall.



Once in place, I added the steering wheel and shaft.

Just to get the position established.

Screen cleared.



Reasonable position and clearance.



Steering wheel removed to lessen the load on the firewall channel.



And the engine side.

Looking good.



At this point @nickwheeler and I were firing on all cylinders.

We seem to be able to just get on with tasks, no boundaries, and total interchangeable rhythm.

We had first cut the MX5 dash support shorter and shorter,



Then added in some steel pipe that curved differently.

Nick had brought his Mig welder in the car and we welded a load through the day.

At this point, tacking in the extensions that are getting attached to the screen support.



Tacked, next thing proper welds and also a few pie cuts to make it all fit together.



Once back in the car, and in position, a check showed the steering wheel was aligned.

Adding the indicator, wiper stalks, airbag and horn push meant one could get a better idea on space utilisation.



And where the shaft goes through the firewall.



What a nice fit this shaft makes in the plate.

More tacking, followed by full depth welding on the bench.



Adding the airbag, indicators and shroud left me with a firewall plate and adjustable clam that Nick had created……

Looking tidy.





So that, despite not looking like a lot of progress, was a good place to get to

.

[Grizz1963]

Carrying on last night.

Once the steering wheel was fully mounted, the brace welded in it was time to check again that the placement was good enough.

Turned out even better than anticipated.





So next job was to start draping and deciphering the wiring loom.







Also placement of the instrument cluster.

Which will be going in straight, rather than angled as planned.




Then removing the clutch pedal, and also cutting off the petrol pedal from the MX5 cluster.




And a flashback…….

I still like this pedal as an option.




@nickwheeler and I continued chatting for a while longer, and then we called it a day.

Busy week for the day job so not expecting any progress this week.

Thanks for checking in.

[Grizz1963]

I must be getting soft in my old age.

Went out and bought these today.



My 20 year old pair eventually self destructed, and the replacement pair never stopped being real uncomfortable

So after dropping something on my foot while building the chassis……..

I am getting old.

[Grizz1963]

Big Milestone ???


Well, depends on what you look at.


@nickwheeler and I were talking and he said the screen support and anchoring the steering wheel would be a major milestone.


At this point one could start draping the loom and planning where stuff goes.


Relocating the air box and MAF meant I need to get some 65mm drain pipe to connect the air box and MAF Sensor.


Plus I need to order 100mm of 63mm inner diameter rubber hose to connect the extension pipe, MAF sensor and Airbox.


I also ordered a hole saw in order to cut some holes for the wiring looms to move about.


Today I bought some safety shoes……. Yes, absolutely shocking.


I must be getting soft in my old age.


My 20 year old pair eventually self destructed, and the replacement pair never stopped being real uncomfortable

So after dropping something on my foot while building the chassis……..

I am getting old.

[Grizz1963]

Something completely random, like me.

I have a few weird friends, well, many I guess.

some not so weird……

One in Siberia, and then Vladimir in Russia.

It is his birthday today.
What I love about them all is this old style mentality of making or fixing stuff.
He wanted a tractor, could not afford one, so built one from scrap.

This is a short video clip of him and friends, doing what friends do.


https://youtu.be/oWWosI0iQ1o

I hope you enjoyed that.

[Grizz1963]

Missed posting this pic at the weekend.

Removed these front stays from the frame.

Immediately improved the look.

Liking this.



Courier delivered the hole saw that Tool Station did not have in stock on Monday.

I was impressed with the service tbh. Not had an out of stock item delivered next day before.

Hole saw is for cutting through the firewall to allow wiring loom and grommets to fit through and close the holes.



Stopped at the local motor spares shop after work, on the way home at 5.00 and pleasantly surprised they were still open.

Always helpful, they did not have the rubber connector hose I wanted, but allowed me to rummage in the back store box of odd pieces.

Failed to find anything 63mm ID for the airbox, but bought a tin of brush on underseal to finish the body tub as well.



Got home and found the connecting pipe for the airbox to MAF unit that one of my neighbors had left, he is a builder and gas man plus a friend.

So a phone call on Monday to Tony saw another small piece of the puzzle come into play.



Day job work week is keeping me busy and knackered by end of day, so unlikely to find time to do little jobs at this point.

Roll on the weekend…………

[Palf70Step]

It was good talking yesterday Rian. I thought the Mazda shell had already made it's trip to a recycler or it's next parts borrowing place? Looking forward to getting back on my 70 some, just waiting on energy to fight the damp cold. I am not quite as use to the damp and cold like you folks, so I am using the I am really old clause to delay things.

[Grizz1963]

Originally Posted by Palf70Step

It was good talking yesterday Rian. I thought the Mazda shell had already made it's trip to a recycler or it's next parts borrowing place? Looking forward to getting back on my 70 some, just waiting on energy to fight the damp cold. I am not quite as use to the damp and cold like you folks, so I am using the I am really old clause to delay things.

Great talking with you yesterday Bill

Sorry I had to get into the soares shop before tbey closed.

Kevin who “owns” the shell had a breakdown of his tow vehicle so failed to collect it in the first week of January.



Sallys little petrolhead (or is it electronic head) grandson.

If is has wheels, he wants to be in or on it.



Seems George, the cat I don’t have likes a car too.

Found him sleeping in the Rezin Rockit a few times.



Had to kick him out when I removed the body.

Not a happy cat.

[Grizz1963]

So…….

After giving George some ham (delivered in the carport) I booted his butt out of the seat.

Figured out a way to lift and remove the body without breaking stuff.

Disconnected the wiring looms that @nickwheeler and I had laid out and strapped in on Sunday.

Then hoisted up the body once I moved the car into the right position.



While doing it, I was wondering why.

I decided to also touch up the chassis that has taken some beating with the fitting and moving stuff about, including the chassis and engine.

Ohh. And one that has bugged me since we made them….. the engine mounts, painted.



I guess the result explained it.



Really pleased with the way it came out.

And all of this in between doing the day job, and being really pi$$ed at the way corporate butt kissing happens, and the way some people are oblivious of just how obvious it becomes when they bend over backwards to kiss their own ring, then coming up proud of themselves while sprouting more corporate bolloxx.

But it pays the mortgage I guess, and I actually really love my job.

One less job for the weekend though.

Onwards in the words of @pauly

[Grizz1963]

[quote author="@nickwheeler" source="/post/2717925/thread" timestamp="1643911860"]





Preliminary work to make the Cortina pedal work the Mazda clutch:

drilled a hole in the pedal to replicate the Mazda offset.
Made new, cross-drilled clevis pin and nylon spacer.

That will be enough to position the master cylinder, but I don't think there will be enough adjustment in the pushrod. If that's the case, I'll make a longer one with a more robust clevis that doesn't need a spacer.

The hole in the Mazda pedal is 10mm but the pin is 8mm. I find that odd. I discovered it after I had drilled a new 10mm hole in the pedal.[/quote]


Long, hard day at work today.

Took me 2.5 hrs to do the 36 miles to Denmark Hill to Kings College Hospital, and two hours back.

Loads of change there, including parking area now a building site.

Only parking available is a private carpark, charging £4.00 per hour or part of it. 3hrs 10 minutes was £16.00 grinds my balls.

Anyway, got in just after 5.00pm and tired.


Then I see your report and my day suddenly turns grand.


Thank you for getting on with these jobs, making my life a breeze Nick.

[Grizz1963]

Over at Dennis’s place this is the current status at Dennis’s place.



He is not a happy guy.

[Grizz1963]

Stole a quick hour yesterday from work.

It was 3’C outside, some chilly breeze and a bit of rain earlier.

SomI fetched the last of the underseal from the garage, added a small bit, around 50ml of white spirit (fake turpentine) to it, and brought the tin into the house, into a pot of boiling water on the stove and melted and mixed it all up to be able to paint it on the wheel arches and inner fenders.

Amazing how much easier it works when warmed up.

Front end complete.



Rear arches all done.



Body itself now ready to go back on, once a few other chassis jobs are done.

Brake lines, fuel lines, part of the loom to be routed under the body, along the chassis.

Fuel tank, and I want to inspect and possibly restore the original which will be a correct fit, and leave space for the rear silencer that @kevins donated to the build. Or else see what is available online in a small, aluminium or similar size.

A few other jobs still to be done.

Today is Sally’s day, (payback comes eventually) so not planning any build time.

Maybe a coffee at the Turkish place as reward.

[Grizz1963]

Well, Turkish lunch happened.

Sally had me all day, till she got bored and went home to do some stuff.

While out and actually having our Lamachun and coffee I saw this out the windows of the restaurant.

Looked like a character from a sci-fi movie, this electric bike stopped outside.

I like it.



After we got in Sally left for an hour, and the new Lodger, maybe for 5-7 weeks, John, the one legged driving instructor got here.

He has already fitted in.

He came down to the garage when he had unpacked and gave a hand getting the threaded bar template sorted.


More in a bit for those of you watching this move along.


.

[Grizz1963]

Quick hour, maybe less this afternoon late when Sally went home to do home stuff.

Popped down, moved a few bits, placed the screen in what could be its final position.



Then quickly made a template for the bolt holes.

Happy with that.



So now the holes need to be drilled in the frame, threaded bar fitted and Tig welded in place, then we are ready.



Ready for what I hear you say.

Watch this space.

[Grizz1963]

Went out by 10.00 this morning.

Cleared up a load of stuff around the workshop, packed materials away wtc.

Then pulled the original fuel tank down to take a look.



Opened up the tank.



Loads of crud inside.



While I was fighting the tank, Nick started to lay out more of the wiring loom and attaching it to the chassis and gearbox/motor.

I removed the tank and then banged it down on the floor in the hope to loosen up some of the crud.

Also had the cement mixer out, planning a load of nuts and bolts and self tapping screws to clean up the inside.

Unfortunately it was not to be.

Rusted out tank.




So now the next trick will be to to get a copy of this tank made up in either steel or ally plate, including the fuel pump etc.

Need to find a sheet metal builder who can copy this and make a tank.

[Grizz1963]

So after the loom and tank work, we carried on with various tasks, most ably led by @Nickwheeler who is a bit like a blood hound, once he cranks his head over and forward, only coffee and cookies or raisin bread slows him down.

The gearbox mount, though probably perfectly adequate, has been bugging him from day one.

So as I had removed the body to get to other bits, he removed it for some strengthening.



Some three handed welding, large ball pein hammer action later, it started to take shape, after the reshaped plate was made up.



Bolted back in place, Nick was a happy bunny.




At this point the body had to go back on again for the next job.



More about it later.

Work now.


PS. An MX5 tank for £40.00 off EBay looks like this,

Ugly.

Really ugly.

[Grizz1963]

Reflecting on the rusted out tank and the options open to me……

I contacted Darren at Unit Engineering in Queenborough on the Isle of Sheppey to discuss options.

So……………

Loaded.



Uploaded.



To be delivered to Darren when I get time, along with the MX5 fuel pump and return valve.

Then hopefully collect a rebuilt tank after X-period of time to fit to the chassis, in exchange for some cash.

I also popped out to fetch some Nyloc nuts and bolts for the rear shock absorbers, as well as the mounting bolts for the screen.



Baby steps every day.

Onwards in the words of @pauly

[Grizz1963]

Part of Sundays “next job” when the body went back on, was to fit the radiator and hoses on some supports, after the initial brackets failed to deliver what we needed.

Tight as a tight fit.



Measure, drill, cut……..



Fail.

Start again, find different materials on the material pile, in the dark.



Welding up the radiator supports.



At this point it was 19.30 on a Sunday evening, so I suggested we pull the plug before starting the top supports that are a touch more complex, and may end up getting incorporated in the fender supports.

But not right now, chilly out at night, makes the extra work less of a pleasure.


.

[Grizz1963]

Went over to The Isle of Sheppey after work today.

I had decided to ask my friend Darren at Unit Engineering to make and adapt the new fuel tank to MX5 hardware.

Price to be confirmed on completion.



A typical old skool Rodder, he runs a few cars, well known down this way.

One of my all time favourites since childhood.

Firenza.





Then this 1000bhp when on Nitrous Chrysler Valiant.



And his Ford Pop.



And his current sideline build, a V8 chopped Beetle.



Funny how great minds think alike.

I really wanted to add a grenade shifter knob to the Rezin Rockit as well.

So I think we are going in the right direction.

One of the things I want on the front screen is a visor.

So Darren let me use his machines and tools to cut and fold a basic visor, which needs finishing and mounting.

Rather large cutter……..





Measure, fold, measure, fold, measure and fold…….

And done.



For now, but it needs some trimming and the angle of the visor cap to be changed.

As well as a bunch of holes and dimple dies to be added.

Should work OK.



Once done, a coffee and cake, and I was on my way, knowing the traffic had died down.


Fooled………

120 minute delay after a motor vehicle accident.

Road closed.

Burger !



Eventually back home I unpacked and had to go look to see how the initial mock up looks.



Angle needs to be changed with the peak dropping quite a bit lower, and also some large dimple die holes punched in the whole length.




Ready for bed, it was a long day.

Later.

[Grizz1963]

[quote author="@31coupe" source="/post/2718928/thread" timestamp="1644483973"]Ooooo that V8 Beetle build is epic!!! Any idea what motor he is putting in it? [/quote]


Rover.

And a big round blowy thing.



Turbo.

[Grizz1963]

Ordered a new spre bottle of Argon/CO2 this week.

Last time was 23 December 2019 it seems….. and then it was £36.00 including free home delivery

This week I ordered a new spare bottle, as the welding @nickwheeler and I were doing on the various parts of the car would use up the existing bottle.

This time it was £50.40 for a refill. Feels expensive but I suspect it is what it would cost with all the price increases seen recently.

I also ordered 25 Bosch 1mm cutting discs, just under £15.00 delivered.

When I got in tonight from Woolwich the rubber hose needed to connect the extended air intake as well for £5.29 delivered.

Small items helping get this build further along.



Friday tomorrow.

Saturday will be mostly garage time and progressing .

Sunday I am hoping KevFromWales will make it here for a visit and to collect the MX5 shell .

Still enjoying this all.

[Grizz1963]

Did a quick job after work tonight.

Been a hard week tbh.

One year in the making…………

Tinted the trucks windows.


BEFORE



DURING



AFTER



TESTED WITH A LIGHT METER.

LEGAL.

DRIVERS SIDE



SCREAMING SIDE



PRETTY PLEASED TO BE HONEST.

ROLL ON THE WEEKEND.

ROCKIT WAITING.

[Grizz1963]

Moved the MX5 up to the house.

All things being equal it should be collected tonight for its trip back up to Wales with KevfromWales

Done some indoors maintenance this morning and made a wooden windowsill for the kitchen.

Next up a load of small fabrication jobs @nickwheeler put on the list he created and that we are still adding to.

Also need to find the fender supports for the Jeep if they exist.
Not sure if I removed them or if they were missing when it got here.

Bad weather and rain forecast for tomorrow.

Ready and waiting




.

[Grizz1963]

So after the indoors work and moving the MX5, I headed down to the garage.

A frw small time consuming jobs were waiting.

After unpacking al the stuff that came off the car in the first place, trying to find the fender brackcets I gve up.

Started to make some brackets, using some steel I had in my pile.



A pair needed of course.





Followed by a pair of radiator brackets, slightly more complex, but done soon enough.



Top of the radiator has rubber bungs to fit these holes.





Happy with that.



Decent remakes and functional.

Lets see what @nickwheeler has to say about them, he is the QC here.




While out there with the cutting disc, I decided to cut the numbers out too from the carcass of the donor, they will be welded onto the chassis later, just for the record.



Inbetween George the cat came down twice to check up on me.


Tomorrow I have the whole day to myself to carry on with the build.

Sally will be at work most of the day, starting at 06.00

Crappy job ehhh.

[Palf70Step]

I remember then work hours, but mine started at 0500. Now sleeping late is 5:00 to 5:30 time frame.