Nearly ready for a full MOT test this time

... Though not before a few swear words.
Fortunately, being I live but one door away from an ex-Honda mechanic I was able to find out quite simply that my lude running rich and not restarting when hot could simply be down to a dodgy thermo sensor. And fortunately it didn't take much research to find out the thermo sensor in a BA4 is exactly the same as the thermo sensor in a BB4

So first job of the weekend to get this thing running properly was to swap thermo sensors. So I removed the one from the BA4 and the one from the silver BB4 and did a quick comparision. Both were filthy, but the BA4's (on the left) was noticably corroded, so I was optimistic

...
So I cleaned the replacement one up...
And then sheered the drokking thing off when refitting it in the BA4!!!

...
I almost cried! What should have been a 5 minute job was now potentially going to be hours if I can't get it out easily
So anyway I got my Dad to get me some bolt removers (the ones with a reverse thread that you screw into a hole). I thought that should do the trick as the remains of the thermo sensor is hollow. So I commenced carefully screwing the bolt remover in, but couldn't see the remains undoing, until before I knew it!... PSSSSS... A sudden release of pressure!

Ok, I'm hoping that was just the bolt remover breaking through the remains

but either way I'm going to have to remove the thermostat housing to drill this bad boy out now. So thermostat housing removed...
And sure enough, no, drokk it, I'd cracked the housing where the bolt remover had pulled it's way in too far

...
Damn cast aluminium!!!

I almost cried again. But I didn't!... I popped to Halfords and bought this...
(Just the way Phil likes it.)
And then did this with it...
Yes I bodged it
But it supposedly cures as hard as steel and bonds to aluminium with no problems, so it was worth a shot (... And I'll keep my eye open for a new theromstat housing

)
So that done, I could finally put the assembly with replacement thermo sensor back on the car. Oh and I gave it a good clean first of course

...
Started her up (No issues as usual). Waited for her to fully warm up (Fan kicked in twice). And then moment of truth, turned her off, went to turn her back on again, and...
[spoiler]She started!!!!

Woooo![/spoiler]
Next job in attempting to get her MOT worthy was to sort the brakes. I honestly can't believe my neighbour drove her to and from the MOT with the brakes as they were! They even did a terrible job of slowing her down to a stop on my drive which is about 1 in 15

Anyway, first job was to switch nearly new discs from the Aerodeck on to the lude as they have exactly the same part numbers front and back. The discs on the lude were exactly the same upgraded drilled and grooved discs, but the Aerodeck's are in much better condition (Aerodeck's on the right)...
Then even the front calipers are interchangable (although subtly different part number suffixes). The Aerodeck's just looked in better condition...
And there was a lot more meat on the nearly new pads too

...
Then apparently the driver's rear caliper was seizing when the examiner had checked them last week (You know, before the MOT was called off

), but sadly the rear calipers are different to the Aerodeck's (The handbrake pick up is in the wrong place), so I started with the passenger side rear and that too had seized. Only one of the sliders was free, the other's boot had come off fractionally and allowed moisture in and corroded...
I got my portable vice out and managed to remove it by beating and taunting it...
How it looked beside the good one (Good one at the top

)...
Then after a clean up and quick wet'n'dry...
The caliper was put back together and re-fitted. The driver's rear however... Both sliders had seized. And this wasn't a job me and my portable vice and lump hammer could manage alone

No, we had to go visit my Dad's bench vice

After some serious strenuous activity I managed to remove both sliders, to again clean up with a bit of wet'n'dry to then re-assemble
Then today I bled the lot and what do you know, she now starts AND stops whenever I tell her too
Nearly there now. Just got to get the rusty hole in the sill temporarily patched and there's a bit of a crack in the windscreen that might be a worry, but I've got a few contacts for both of those now

So fingers crossed mid-week she should be back in for a full test this time
