BB1 Scrapyard Dog - Mugen sides

[vanzep]

still couldnt get the driveshafts to seperate from the hubs so its off to get heated up with oxy in the last attempt to free it off
this is the most stumped ive been with a lude - very frustrating to be 5 minutes away from finishing the job only to be thrown into melt down mode with the lude sitting on axle stands for weeks on end

i cant find any abs hubs so still going down the route of fitting new bearings and lower ball joints - not the easy/low cost option i was planning on

ive also had to replace the upper wishbone ball joints and ive poly filled round the oem mounts and given them a lick of paint
at least that job worked out ok



old mounts


cleaned up, brush painted and reinforced with some sikaflex


new ball joints




Total cost of upper arm refurb - £30 (£15 per side)

[vanzep]

as the lude has been sitting on axle stands for the last 3 weeks i decide to replace the clutch and flywheel and also 3 out of the 4 engine mounts

got most of it done today with only the rear mount to change over and then the gearbox goes back in and it all gets bolted back together - theres a lot more parts to go back on than on my BB4

pic of engine bay before work started


pic of engine bay once all the stuff was removed


gearbox out - thrust bearing was knackered but friction plate and pressure plate still had some life left in them


old clutch vs new atr clutch kit


kaiten lightweight (5.1Kg)flywheel ready to go on


gearbox cleaned up inside and out and new bearing fitted
note the odd connection on the vss - doesnt look like the one on the BB4


lsd gearbox in car is M2B4 and its the 617th one to leave the production line.


kaiten flywheel installed


es poly front mount supports and sikaflex refurbed gearbox and rear engine mount


got the clutch and pressure plate fitted last thing but forgot to take a pic

hopefully start bolting it all back together tomorrow/saturday

still looking for some front hubs so i can get the car back on the road

[newkid]

You'll love the flywheel bud

Btw it's 4.6kg

[wurlycorner]

More brilliant work on this car, well done vanzep. The top arm bushes looked in really good nick to start with actually - much better than many of mine are.

Sorry to read of your grief with the driveshafts, what a complete arse!

Be interested to hear how the engine vibrations are for you after fitting both front/rear ES inserts and polyfilling the side mounts. I really don't like the way Lisa's engine feels at the moment when pulling away after ES inserts in front/rear - it doesn't take to a clutch slip type pull away/hold at a junction, at all. The whole car judders and the dash shakes like a bag of nail. I think that's because one of the side mounts is torn though, which is why I'm interested in feedback...

[Greg-SiR]

Your right on the Vss it looks as the connection plug leaves the unit on a wire,i was going to swap my Bb2's into Bb4 as the mounting bracket was gone and the piece itself would dislodge under load but only difference on my cars was the plug connection,the Bb4 is plugged in vertical and the older Bb2 is horizontal which doesn't make too much bother anyhows as the top of the unit can be swapped over.

Great work on the clutch and all that entails i would love to have done this job on my car this week instead of forking out for it and learned from it

I'm loving my new setup with the flywheel and Hd clutch,such a different car and so much more fun to be had,first drive after been fitted had my head nodding through downshifts,i think my engine mounts will be next on the agenda.

Hats off

[chrismc]

Be interested to hear how the engine vibrations are for you after fitting both front/rear ES inserts and polyfilling the side mounts. I really don't like the way Lisa's engine feels at the moment when pulling away after ES inserts in front/rear - it doesn't take to a clutch slip type pull away/hold at a junction, at all. The whole car judders and the dash shakes like a bag of nail. I think that's because one of the side mounts is torn though, which is why I'm interested in feedback...

The track car has ES inserts front & rear. No massive vibrations & response/gear change are night & day better.

I don't suppose a knackered side mount will be helping matters

[vanzep]

Thanks for the kind comments - its has been a bit of a slog
i was a bit nervous about taking on this job as there seems to be some stuff in the engine bay that ive not seen before like the weird vss and copper grounding plates that fit under some of the bolts on the electrical stuff - just hope i can remember where it all goes when i build it back up

ive dome the same thing as i did on my BB4 clutch, flywheel and engine mounts in a oner- when you in there you might as well do the mounts as they are easier to access - the 3 that ive replaced on the BB1 were all split but not broken - just hanging on by a thread so im glad that ive gone the "extra mile" so to speak. I will sikaflex the passenger side mount when i do the cambelt and tensioners as its got to be removed anyway.
I do expect some more vibration but ive always gone with sikaflex so first time using es poly front mount so will see how it compares to the BB4 geek:

[vanzep]

Got the gearbox back in today
massive thanks to @3rd gen steve who took on the task of manhandling it back into place - not the easiest of jobs! I knew that i just did not have the outright strength to do it myself.

pick of ATR clutch installed


everything put back together ( well almost)


couple of new parts fitted - new battery tray as old one had been butchered to allow fitment of wrong sized battery
also fitted new front radius rod - simply because i had one

new batt tray is on the left


new front radius rod&hardware


still up on stilts - waiting for new or reworked front hubs


note to self:still to do
do up im mani stay bracket at back of the block&replace ps fluid
check alignment of gearbox mount

[vanzep]

Loads more parts have gone on the lude - more than i intended to do in one go.
I couldnt find any good condition abs hubs at a decent price and i had just about given up when @newkid called me and said a friend of a friend had just turned up at his door with an orange 4th gen on the back of his flatbed. There was no engine or gearbox and the car had been damaged loading it up onto the flatbed with a forklift The breaker had ABS hubs and TCS and looked like it had been someones build that was near completion but for some reason abruptly ended but damage in transit and no engine and box meant it was always going to be a breaker. Real shame as the car was in very very good condition inside and underneath with no visible rust
When we got a better look at the car the next day we could see it had recently been fully polybushed, new braided brake lines, new roll bars and drop links front and back, new track rod ends etc etc
So yesterday we stripped off the hubs,lcas,wishbones and uprated drop links. Everything came apart easy and all parts were either new or uprated with es poly

Not wanting to waste any time we fitted the following to my BB1 this afternoon:

front lcas fully polybushed
uprated drop links with es poly bushes
front top wishbones with es poly bushes and new ball joints
good condition front abs hubs with new lower ball joints
refitted the brakes and front discs
refurbed driveshafts and intermediate shaft

also filled the gearbox with 1.8 litres of Honda MTF3 and refilled the power steering with Honda PS.

All went well and we got the wheels on and the car back down on the deck for the first time in 5 weeks , then it rained, we got soaked, car wouldnt start, gave up and went home
I think its just the battery is flat and needs charged up
So near and yet so far

Sorry no pics but hopefully will get some tomorrow once i get the thing started

big thank you to @newkid for helping save my BB1 (again)

[newkid]

No worries man.