:: Diary - May 2005 ::

:: Sunday May 1 2005 ::

I still want to check the ECU diagnostic codes, but last time I tried my Gunson's fault code reader, it didn't work. I don't know if it's the tester (which has been lying in my shed for 5 years with a flat battery) or the wiring of the car.

I decide to resolve this dilemma today, by making another tester (I'm not buying one, they cost about £60 or so). Down to Maplins for an LED, a wee switch, and a wee box to put it in.

And here it is. After an hours worth of drilling and soldering and stuff, I've made a wee tester box - total cost £2.84. Note the use of wee split pins as terminals - the advantage being that you can spread them slightly to make sure they are a good fit. I think I'll call it the haggis-yzer.
What you do is plug the red wire into the top of the triangular connector, and the two black wires into the other two. You take a wire from the black connector to the positive battery terminal, then you make sure the wee button is "off" and switch on the ignition. Then you switch on the wee switch and the LED light comes on, and flashes the engine system's diagnostic codes. In theory.

The question is, does it work? Well the proof of the pudding is in the eating, and as a chicken rogan josh with my name on it arrives at this moment, the eating of the pudding will have to wait until I have eaten all my dinner.

<---chomp chomp chomp--->

Right, back out and wire it up to the car - and it works! It sodding well works!

Well sort of. The problem is that it doesn't actually flash the codes - exactly the same problem as my other tester. I need to check the cars wiring.

Bummer.

:: Thursday May 5 2005 ::

Was chatting to a mate about the problems with the car diagnostics.

He says that it sounds as if the tester isn't outputting a signal. He suggests that it could be the ECU earth, which rings a bell because the ECU sits loose and isn't obviously earthed to anything. I need to have a look at that, but don't know when because I am away the next two weekends.

:: Thursday May 12 2005 ::

Took the car to work today, so that it could revise for its MOT test tomorrow.

Nice warm weather, very pleasant indeed! No sign of the intermittent misfire.

:: Friday May 13 2005 ::

MOT test today. I have done no preparation or checks whatsoever.

It passed. Naturally.

The garage gave me one of the brand new-type MOT certificates that are kept on-line, so you can tax the car without taking all the documents into the Post Office. I am not overly bothered about this as I have never suffered a hernia carrying an extra piece of A5 paper. It obviously benefits some however so I'll go along with it.

There is a litle peel-off bit in the corner which the garage says must be displayed on the window. It's the new law, don't ya know. Em, no, it isn't... The MOT website confirms that it's only to remind you when the next test is due.

I decide not to go back and take this up with the garage in case they suddenly notice the dodgy steering bush which has needed replacement since I first got the car...

:: Monday May 16 2005 ::

Finally fitted the shiny-shiny super-duper rocker covers.

The rest of the engine bay looks rubbish now...

Also, after checking various handbooks and manuals, I decided to re-gap the plugs to 1.0 mm then bottled it and settled for 0.9 mm. This is a desperate attempt to address the wee misfire that comes and goes...

:: Saturday May 21 2005 ::

Just remembered that the nearside inner wheel arch was dislodged on the last run I was on, and is only held on by a plastic cable tie. Of course, in typical TVR-fixing style, about 5 minutes after I start, the heavens open, and I get soaked. After an age of struggling with different-sized self-tappers, I finally get the wheel arch in place.

:: Sunday May 22 2005 ::

The annual club run - a total of 320 miles by the time I get to the start and get home from the finish. Again, the weather isn't kind but still an excellent day.

Click here for photos of the day!

One advantage of driving such a huge distance is that the misfire comes and goes and I get a chance to diagnose the circumstances - and it seems to happen more during the damp / rainy bits of the drive. My attention is turning to the ignition leads (the only ignition bits I haven't replaced).

Another disadvantage of the rain is that water pishes in the top of the windcreen and drips off the roof above the interior mirror. This is ever so slightly distracting.

:: Saturday May 28 2005 ::

When I got home after the TAG run last weekend, I noticed that the exhaust sounded as though it was leaking. I had hoped that this was due to the removal of yet another clamp on the road surface but a quick inspection confirmed that, as well as losng a clamp, I had moved firmly into PITA land...

This is a crack in the exhaust manifold - well more of a split weld really. I confess that I had noticed this about 3 weeks ago and had effected what I hoped would be a semi-permanent repair, with a huge dollop of gun gum. Anybody with half a brain knows that gun gum doesn't work in these situations. I'm learning - I have now worked my way up to the half-a-brain club.

A rummage through the advice on various web sites discloses that the best method of repair is to replace the manifolds. They cost £Ohjeesi'mnotpayingthat. Each.

Added to the expense, is the fact that replacing the manifolds involves unbolting them from the cylinder heads. Looks easy - 6 nuts each side. These nuts are invariably rusted to the studs, the studs shear on first glimpse of anything spanner-shaped, and replacing the studs involves taking the engine to bits...

Not an appealing prospect.

I pop down to Halfords and buy a couple of brazing rods. Cost about a tenner.

Out comes the trusty blowlamp, flame set to max. On go the long sleeved overalls, the rigger gloves and the safety goggles. Half an hour later and I have sealed the crack with braze. Not a pretty sight, admittedly, but at least it doesn't leak any more! A coat of paint and it will look pish (which is a step up from crap, as it is just now). I'm an engineer (only just), not an artiste.

At least it worked!

:: Sunday May 29 2005 ::

Chipped away the brazing flux and then painted the exhaust manifold I repaired yesterday - it looks not too bad now! Good enough for now until the rest of the manifold falls to bits...

Later, went out for a run when I bottomed on a speed hump and would have scraped another exhaust clamp off, if I had got around to replacing it since the TAG run. I think I need to stock up on those things. I replaced it when I got home, with the last clamp I have left. Note to self - order some more. Lots.

Also noticed that the new downpipes are flat on the bottom, where they have been scraping on the road. Oh dear.

Then I decided to reseal the windscreen by sealing the edge with black silicone. I am getting good with that stuff. Practise makes not quite perfect but a lot less messy.