S2 Sierra rebuild write up

Re: S2 Sierra rebuild write up

Postby Adrian(doc3400) » Sat Dec 20, 2014 12:30 pm

Forgot to do updates for nearly nine months... I'll make this quick.
Its still running, getting abused everyday going to work although she's had a few minor issues since the wiring incident. I never did find out the exact cause however a lot of the earth wiring was damaged so I suspect it was related to a dodgy earth somewhere. Not had any problem since but planning to fit underbonnet relays for the headlights over the christmas holidays.
I've gone back to the 8" steel wheels now but the tyres have changed a little. Its now a little less chelsea and more tractor...
So its gone from this...
Image
My Dutton Sierra II by Adrian Southgate, on Flickr

through this...
Image
Sierra II by Adrian Southgate, on Flickr

and now this...
Image
IMAG0476 by Adrian Southgate, on Flickr

I need to get a daylight dry picture of it really. No mods to the suspension or spacers were made however if you look in the last pic you can see the front part of the ally undertray to keep 'stuff' out of the engine bay. That's being made in situ as its the easiest way of making it fit. Eventually it will stretch nearly down to the diff under the drivetrain to protect all the running mechanics. Getting a spare might be an issue so I reckon I'll have to settle for some form of 'compact' spare on a 14" weller.
I have a big job list over the next few weeks providing mother nature keeps her nose out and the rain stops.
Last edited by Adrian(doc3400) on Tue Oct 20, 2015 2:42 pm, edited 1 time in total.
DUTTON SIERRA S2
1988 LEGERRA S1
1989 LEGERRA ZS - BEING RESTORED
1990 LEGERRA ZS
1990 LEGERRA ZS sunday car
PHAETON 2
PHAETON 3
PHAETON 4
User avatar
Adrian(doc3400)
Advanced Member
 
Posts: 202
Joined: Fri Jun 04, 2004 7:37 am
Location: Bolton (DOC membership secretary)

Re: S2 Sierra rebuild write up

Postby Paul S » Tue Dec 23, 2014 11:47 am

Like it with those tyres on! Is the prop shaft still behaving its self?
User avatar
Paul S
Advanced Member
 
Posts: 177
Joined: Sun Apr 20, 2008 9:43 pm
Location: Potters Bar, Herts

Re: S2 Sierra rebuild write up

Postby Adrian(doc3400) » Tue Dec 23, 2014 11:47 pm

Prop's luvverly Guv. Thanking you :D
I still think it drives better with the big rubber on, maybe not as fast away from the lights :o but comfy.
Time for a bit of xmas holiday therapy though.
DUTTON SIERRA S2
1988 LEGERRA S1
1989 LEGERRA ZS - BEING RESTORED
1990 LEGERRA ZS
1990 LEGERRA ZS sunday car
PHAETON 2
PHAETON 3
PHAETON 4
User avatar
Adrian(doc3400)
Advanced Member
 
Posts: 202
Joined: Fri Jun 04, 2004 7:37 am
Location: Bolton (DOC membership secretary)

Re: S2 Sierra rebuild write up

Postby longboarder » Wed Dec 24, 2014 10:42 am

certainly appears to fill those arches, correctly. :)
longboarder
Advanced Member
 
Posts: 70
Joined: Thu Oct 14, 2010 1:30 pm

Re: S2 Sierra rebuild write up

Postby Adrian(doc3400) » Wed Dec 24, 2014 6:01 pm

Its damn close to fouling on lock but doesnt quite touch so I got away with it :lol: Any bigger or lower and i'd be stuffed. Still need to modify the rear, take the lowering blocks out and fit multileaf springs.
DUTTON SIERRA S2
1988 LEGERRA S1
1989 LEGERRA ZS - BEING RESTORED
1990 LEGERRA ZS
1990 LEGERRA ZS sunday car
PHAETON 2
PHAETON 3
PHAETON 4
User avatar
Adrian(doc3400)
Advanced Member
 
Posts: 202
Joined: Fri Jun 04, 2004 7:37 am
Location: Bolton (DOC membership secretary)

Re: S2 Sierra rebuild write up

Postby longboarder » Mon Dec 29, 2014 1:07 pm

got 2 sets of multi leaf springs. One with 4 leaves and one with 3 leaves, any good give me a shout, I'm fed up tripping over them. All clean and painted too. :D
longboarder
Advanced Member
 
Posts: 70
Joined: Thu Oct 14, 2010 1:30 pm

Re: S2 Sierra rebuild write up

Postby Adrian(doc3400) » Wed Dec 31, 2014 5:49 pm

I can see the DPD man hitting me quite hard if he has to deliver those Steve :D
I'm still trying to extract the bushes from mine as they are rusted in but I may take you up on that offer if it gives me much more hassle. Any idea which ones have the higher rating?

I have had a little missfire on the Sierra for ages which is why I was looking at the accuspark setup. Tested two coils, two condensers, dwell and static timing, mixture and mains etc but it still has a 'lump' in the tickover, its not quite perfect if you see what I mean. Anyway, checked stuff again today and come to the conclusion that next time the rocker cover is off I'm going to check the back of the cam shaft for a stamp as it feels like it has a non-standard camshaft. Bearing it came out of a kit car originally then its always a possibility.
DUTTON SIERRA S2
1988 LEGERRA S1
1989 LEGERRA ZS - BEING RESTORED
1990 LEGERRA ZS
1990 LEGERRA ZS sunday car
PHAETON 2
PHAETON 3
PHAETON 4
User avatar
Adrian(doc3400)
Advanced Member
 
Posts: 202
Joined: Fri Jun 04, 2004 7:37 am
Location: Bolton (DOC membership secretary)

Re: S2 Sierra rebuild write up

Postby Adrian(doc3400) » Sun Jan 25, 2015 7:48 pm

Bloody cold under the Sierra yesterday however I did manage to replace the rear shocks. The originals were bad, the left one dropped to maximum travel length as soon as it was released from the lower bolt so not much life left in that one :o
New ones are completely standard escort (read budget brand) however they were new items so had to be better than the old. Near side went straight on, no problem at all, plenty of copperease on the bolts and voila, new shock. Offside however demonstrated typical dutton chassis alignment issues as the chassis bracket was pissed by half a bolt diameter (1/4 inch). Its exactly as supplied from the factory so I doubt if those have ever been replaced before. I elongated the hole and fitted washers, added to the list of 'weld it up later' jobs to do if the body ever comes off.
Relocated the reversing light off centre and fitted the towball drop plate, still not low enough to tow a long trailer without risking scraping the back though, looks like I need one of those silly big landy ones if i'm going to pull a car trailer with it. Maybe just build the trailer to match the car, it would probably be cheaper. Couldn't find the tow ball bolt box so left my towball off for now.
Been for a drive today and rear end bounce is reduced over speed ramps, i'll see in the morning if it's stopped the slight oscillation I was getting on the motorway.
Engine is still not quite right. I'm reluctant to spend money getting it tuned properly as it will probably double the cost of the car. Still need to buy a few little bits though. Thermostat housing would be good as I have 2/3rds of the radiator grill covered at the moment to keep engine temperature up at speed, problem with that is it gets a bit too warm in traffic and I do find queues in the mornings going to work to be a bit worrying.
10 days without a real ciggy and hopefully being able to spend some of the savings on car parts this month, maybe that tune up isn't such a bad idea after all.
DUTTON SIERRA S2
1988 LEGERRA S1
1989 LEGERRA ZS - BEING RESTORED
1990 LEGERRA ZS
1990 LEGERRA ZS sunday car
PHAETON 2
PHAETON 3
PHAETON 4
User avatar
Adrian(doc3400)
Advanced Member
 
Posts: 202
Joined: Fri Jun 04, 2004 7:37 am
Location: Bolton (DOC membership secretary)

Re: S2 Sierra rebuild write up

Postby Adrian(doc3400) » Mon Aug 17, 2015 12:15 am

While looking for my elusive misfire I sort of found a few minor breakages. The alternator bracket for one...
So here is the guilty bit or bits... given a quick brush over with the dirty brush just to remove the road dirt. Clean break caused by using a 3ft crowbar to tighten the fan belt probably...

Image
IMAG0589 by Adrian Southgate, on Flickr

A few minutes later it now looks remarkably like Mr Blobby...

Image
IMAG0591 by Adrian Southgate, on Flickr

Yeah I know its messy and I should have cleaned it a bit more first but I can't get to the blasting cabinet at the moment, point is, it's now one piece again so out with the flap disc in the grinder and dress it back a bit so it will actually fit against the engine.

Image
IMAG0593 by Adrian Southgate, on Flickr

And a bit of a tidy on the bolt side with the dremel..

Image
IMAG0594 by Adrian Southgate, on Flickr

Should be good for a few years more service providing I can use a smaller bar for doing the fan belt.

So on to the real reason for this update. I re did the tailgate. It was a standard side opening, hinge drooping bodge job. Just there to fill the back door hole so I decided to make it 'useful'.
Binned the old hinges and mounted the top with mini units and small wedge spacers. Mini boot hinges sit at an angle which would stress the joint if not wedged. Now I have resin masters I may try to cast some in ally or white metal at some point but the resin ones seem to be working so on to the next step.
Making a drop down bottom 1/3rd out of scrap ally from work, good practice for welding skills as it will all be covered in the end. I deliberately made the frame smaller than the hole so I had room to fit a cover after, this is a basic frame made from U channel (a scrap frame from a fixed projector screen) and some 1 inch tube (more scrap from server racks at work). Using the old escort estate seat hinges with a lump removed and held to the chassis using M10 U bolts.
The hinges sit behind the bumper on top of the chassis with only a small amount of fibreglass removed to allow them to slide into place.

Image
IMAG0596 by Adrian Southgate, on Flickr

These have three screws countersunk from the bottom, one through into the rectangular U channel and two into the tab which is welded to the frame. The original hinge shape is bent over at nearly the exact height required to clear the back body step which is why I used them. The 'completed' skeleton for the tailgate is still a bit rough but will happily support my body weight, more than can be said for the original dutton fibreglass.

Image
IMAG0601 by Adrian Southgate, on Flickr

The two securing bolts are salvaged from HP server racks, I do have a few spares if anyone needs a couple. A new seal helped a lot, the old one was a mash of little bits. It does need the stops making, something to keep the tailgate level so it can be used as a step/seat. The body isn't tough enough to use with wires or chains so it will have to be a stop fitted to the hinges, haven't quite worked out how thats going to work yet.
Lets move up to the top half of the door. I removed the bit at the bottom with an oscillating saw, stashed that in the garage for 'modification' into the cover, needs a fair bit of work. So now i'm left with the window and the vertical panel below it down to the lower body line. Had to trim it a bit here and there to fit over the ally bit and the bolts but got the basic carcass right and it now shuts flush against the new seal. problem is it doesn't stay there so its going to need a locking device. I want to keep the back of the lower section clean of anything that may snag on clothes or shins so it will have to be side mounted, both sides need to operate together so more bits blagged from the scrap at work got me a locking bar set from another server rack with a double sided arm to fit to the lock.

Image
IMAG0600 by Adrian Southgate, on Flickr

This is connected with two steel rods to a couple of latches I originally bought for the ambulance about ten years ago. Never used them and they have been 'spares' ever since.

Image
IMAG0598 by Adrian Southgate, on Flickr

The ally channel it's all bolted to came from a scrap something at work years ago and the rectangular plates I've had since the late 80's, now finally put to good use. There is another set of plates on the outside of the door so the fibreglass is sandwiched between the two ally plates. When the door is closed the latches fit into the side plates bolted to the inside edge of the door frame. Small holes drilled into the side plates and joined up with the dremel give them something to grip onto. Once I am happy with the lock and mechanics this will all be concealed behind some new fibreglass work which will complete the bottom of the door and 'make safe' all the sharp edges lurking under the ally bits.

Image
IMAG0597 by Adrian Southgate, on Flickr

The other new addition today is a new back box to replace the straight through pipe which was SO noisy. Those of you unlucky enough to have been anywhere near it on the sunday night when I left Stoneleigh will know just how loud 103Db is. This little beast cost just £29.95 and came with a reducer, support bracket and natty sticker. The chap (Hornet Exhausts) also sells kits in mild steel from £89.99 upwards dependant on bore of pipe with enough pipe, bends and two silencers , for a full system. He is happy to communicate with anyone looking for a specific kit of parts and put things together for a decent price. A full 2 inch system for the legerra in mild steel would be about £120 by my calculations, reasonable value for a DIY exhaust system.

Image
IMAG0595 by Adrian Southgate, on Flickr

This is the end of this chapter of war and peace... however I still need a pair of strut tops, preferably roller bearing ones as mine are well past it. I'll tackle the fibreglass repairs next time.
DUTTON SIERRA S2
1988 LEGERRA S1
1989 LEGERRA ZS - BEING RESTORED
1990 LEGERRA ZS
1990 LEGERRA ZS sunday car
PHAETON 2
PHAETON 3
PHAETON 4
User avatar
Adrian(doc3400)
Advanced Member
 
Posts: 202
Joined: Fri Jun 04, 2004 7:37 am
Location: Bolton (DOC membership secretary)

Re: S2 Sierra rebuild write up

Postby Adrian(doc3400) » Tue Oct 20, 2015 2:04 pm

Been lazy and not updated for a bit so here is a couple of shots of the replacement multi leaf springs, usual before and after jobs. The Sierra currently runs single leaf and doesn't have much of a load capacity before it starts to sag, i'm hoping these will provide a softer ride when unloaded but allow it to lug a bit more weight.
Image
IMAG0603 by Adrian Southgate, on Flickr

Had to use the air chisel to remove the old metal sleeve from the front eye but the new bushes don't use it. Rear shackle bushes were an easy fit, the old ones are triangular rubber which gave the impression it has 'gone' even though it hadn't.
Won't know about the chassis bushes until I start stripping the old ones off the Sierra.
Image
IMAG0604 by Adrian Southgate, on Flickr

New saddle clamp bushes, the old ones were most definitely shot.
Image
IMAG0605 by Adrian Southgate, on Flickr

Got the little handbrake rod bush too as that's perished, steering rack is already done, ARB is already done, so just the TCA bushes to do and fit.
DUTTON SIERRA S2
1988 LEGERRA S1
1989 LEGERRA ZS - BEING RESTORED
1990 LEGERRA ZS
1990 LEGERRA ZS sunday car
PHAETON 2
PHAETON 3
PHAETON 4
User avatar
Adrian(doc3400)
Advanced Member
 
Posts: 202
Joined: Fri Jun 04, 2004 7:37 am
Location: Bolton (DOC membership secretary)

Previous

Return to Sierra S1, S2, S3, Drophead, Rico, Beneto

Who is online

Users browsing this forum: No registered users and 1 guest

cron