Eunos Chump

Finished assembling the OS front suspension this evening. I installed new alignment bolts here, it was quite easy (though access to the rear bolt was bloody awkward) and I was surprised how much adjustment is available - there's huge scope for fiddling! I aligned it as best I could but it will need a visit to a specialist. Put the new strut on too, easy job with the alignment bolts loosened.

I got that pesky aircon compressor off this evening by chopping the head off the knackered bolt, then applying violence. With it's mounting bracket it's a lot of weight (perhaps 10Kg), I don't need to be carrying that about. I've got enough weighty equipment attached to my own body :) The boots for the shocks arrived today, usual next-day service from MX5Parts. So far I've assembled the NSF strut. They're not a snug fit like they are on the OEM shocks, but that means they won't be subject to constant movement so hopefully will last longer. Bought a full set of alignment bolts too, needed doing.

Spent an hour trying to get the damn aircon pump off, but no joy. I've drained the coolant and removed the hoses to improve access, but there isn't quite enough space to hammer a socket onto the rounded-off bolt. Thinking about chopping it's head off... hmmm.

Not much progress this week, been busy at work and getting home late. I've decided I should fit new dust boots to the shocks despite them being stupidly expensive, which means I'll have to whip the rear struts off again to fit them (not done the front yet). I know the drill now though, should only take an hour. I've removed most of the aircon components now, it didn't work anyway because the condenser was holed and the occasions when it might be useful are very rare. The compressor isn't going anywhere yet because it has a rounded-off bolt, and access is very difficult. Once that heavy lump of metal is gone there'll be plenty of space for an intercooler.

I had a day's leave today, went on a date with Mrs B to the New Forest and we had an excellent time. Still managed to fit some work in during the evening though, I've replaced the OS track rod end and steering rack gaiter and removed and disassembled the strut. I managed to do the latter without loosening the alignment bolts on the lower wishbone (manual says you have to), hopefully I'll be able to fit the new one using the same procedure. I used a universal gaiter kit from a nearby factor, 1/4 the price of the Mazda kit and they're made of that really stretchy rubber which will allow you to fit them without removing the track rod end.

I've made huge progress this weekend, despite not starting work until the afternoon and wasting some time on fruitless quests for fine-threaded nuts. I did however get a complete set of droplink bolts/nuts from the local Mazda/Fiat dealer FOR FREE! He didn't have an exact match but found me some from workshop spares. That's fine service and makes up for them charging me £150 to adjust the tappets on my X1/9 a decade ago. Saw a Fiat 500 there for the first time, doesn't look quite so good in the metal unfortunately. Every time a new small car appears I consider buying one (started with Ka, through Citroen C3, C2, Panda, Grande Punto), but so far I remain unseduced. A reasonably specced 500 will set you back almost £11K which looks ridiculous compared to a Panda, and once the novelty has worn off you can bet they'll be knocking them out nearer £8K. Anyway, I digress. I reassembled the refurbished drop links with Polybushes, they look good enough to eat don't they

I was tempted to stay in this evening and watch Kim Wilde videos , but I decided to put my trousers back on and go and finish the rear struts instead. I was able to remove the old NSR strut by levering down the wishbone, but couldn't get enough clearance to put the new one on (despite it being theoretically shorter). I had to detach the hub carrier from the upper wishbone in the end, thankfully it came apart without the nut, bolt and bush coming to harm. Once I locate some new bolts for the droplinks, I can get the anti-roll bar on and that'll be the back end finished!

Painted the underside of the boot today with grey Smoothrite, you could eat your dinner off it now! Once I get some Dinitrol over the top, that'll last another 1000 years. Fitted the OSR Koni strut, can't wait to give them a try. Insured the car with A-Plan today, cheaper than Aon but it's still almost double what I was paying before it was modified. Shame the car won't go 100% faster too.

It wasn't until I disassembled the OSR strut that I realised how truly knackered it was. Yes, it looks awful but then it would after a few years under the car, but it was butter-soft in comparison to the new Koni and took almost a minute to recover from being fully depressed. I've not fitted the new one yet, the top shock mount needs to be drilled out from 10mm to 12, but neither of my drills can accomodate a drill bit that wide. Never bloody easy, is it? The rear subframe is looking good enough to eat with it's new coat of Smoothrite. Lick it, go on, you know you want to! I've learnt not to attempt cleaning brushes after using Hammerite, it's easier just to use cheapo disposable brushes. I got my 500-piece mixed bag of nuts and bolt from Namrick today, good value at £21 delivered. Sorting them out wasn't much fun though, and I need 6 more bolts to replace the rusted droplink ones. Arse.

Spent about an hour replacing the fuel filter this evening, from the look of it the old one had been on there for YEARS. There's a good article on this job here which claims you can do it in 10 minutes... nonsense. Ordered the Koni sport kit today, comprising springs and adjustable shocks. Ordered a pair of track rod ends too (boots perished), I could use some steering rack gaiters too but I'm sure I can get some universal ones cheaper. Precious brass!

After wasting most of the Xmas break stuffing myself with crisps and watching rubbish TV, I've at last taken a serious stab at all the work required before the 5 goes back on the road (March is my aim). I've cleaned up and repainted the rear subframe, this was a horrible and time consuming job not helped by me spilling half a tin of Hammerite on the floor. I've removed the spring/shock from one side, this gave better access and let me check the condition of the wishbone bushes. They all look fine, which saves me the dilemma of having to choose between standard or poly bushes. Huge doses of WD40 are ensuring no more bolts or threads are shearing when I'm removing stuff, but most of the hardware is too rusted to consider putting back. I'm going to order a load of new galvanised ones from Namrick . I've also cut the hole in the bumper for the additional exhaust. It was a sod of a job and I wrecked about 5 hacksaw blades in the process, was tempted to use TNT.

Bored of model trains now, I only want to play with cars again. I said that particular hobby wouldn't last long. It's not much cheaper than tinkering with cars anyway - some engines can cost almost £200! I could buy a lovely old Bluebird for that money, with enough change for an Almera for really special occasions such as picking up a knighthood or entering a grand prix. Spent today under the 5, what better way to spend precious holiday? Removed the exhaust complete with cat (that came off OK after a couple of doses of WD40 and a big breaker bar). Drilled out the sheared anti-roll bar stud (that was easy too with new drill bits), and started cleaning up the rear suspension for a new coat of Hammerite. The lateral box section above looked well rusted, but happily it was just surface corrosion. Can't decide if I should take the suspension arms off and do a complete rebuild (poly bushes, etc).