VAK 1972 Clan Crusader

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Re: VAK 1972 Clan Crusader

Post by bks974c » Sat Aug 25, 2018 9:47 pm

IMG_20180813_190051.jpg
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Re: VAK 1972 Clan Crusader

Post by colimp66 » Sat Aug 25, 2018 10:31 pm

Oooooohhhh!! That doesnt look to clever Scott.
Is the block reusable or will it need a new liner?

Col.
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Re: VAK 1972 Clan Crusader

Post by bks974c » Sat Aug 25, 2018 11:00 pm

Bores are perfect, mirror finish not even a scratch may just a little over size.

What your probably seeing is the reflections :roll:

Looks like a set of 73mm pistons required and good to go.

Scott
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Re: VAK 1972 Clan Crusader

Post by bks974c » Mon Aug 27, 2018 6:52 pm

With Bo'ness Revival - Classic Car Show and Hillclimb this weekend - http://www.bonessrevival.co.uk/

I need to finish the engine rebuild and get it installed.
IMG_20180827_120356.jpg
IMG_20180827_120400.jpg
Getting the head on when well, I knew one of the shims needed changing as I had checked clearance before dismantling - No. 4 inlet 5 thou rather than 7 then I couldn't find my new digital micrometer :evil: Must still be a home :o

Resorted to filing the existing shim and refitting, still tight so removed the cam and carrier again. One of the buckets stayed behind as they do and I see this.
IMG_20180827_140408.jpg
On number 4 - related to the other issues ? very possibly. The camshaft (R21) is unmarked -perfect infact

Close inspection of the others reveals two with what appears to be a couple of tiny pits.
IMG_20180827_140416.jpg
Looked at some others I had to hand reveals the pits are quite common :shock:

So game over for today as I need buckets from home, rather than changing individual buckets I think the best solution is to fit another cam carrier and its matching buckets fortunately I have said item although this will undoubtedly mean re-shimming :(

Plus the micrometer not in the house :evil: hey ho tomorrow is another day.

Scott
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Re: VAK 1972 Clan Crusader

Post by Lotus-e-Clan » Mon Aug 27, 2018 7:08 pm

Bum.

Are they Cosworth steel buckets (expensive)? :o

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Re: VAK 1972 Clan Crusader

Post by bks974c » Mon Aug 27, 2018 7:16 pm

No, standard Imp items. Engine rev limited to max 8500 so hopefully Cosworth items an unnecessary expense.

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Re: VAK 1972 Clan Crusader

Post by bks974c » Tue Aug 28, 2018 9:01 am

After much thought about the BAD practice of using used buckets I think I've decided to just replace the two on number four rather than take carriers from their matched cams.

Anyone with practical experience of reusing buckets with a different camshaft ?

Scott
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Re: VAK 1972 Clan Crusader

Post by Lotus-e-Clan » Tue Aug 28, 2018 9:33 am

I've used std cast bucket sets with their respective carriers for different cams -never had a broken bucket - nor an eroded pot-holed one either so I've been lucky. I've never mixed std used buckets mind you. I've used std buckets revving way beyond 9000 rpm - about 11000 on one occasion in first gear (R17 Chesman 998) - during red mist attacks as a youth!

I think Pete Richards has mixed std buckets IIRC - hopefully he'll be along soon to put that one straight.

The Clan currently has Cosworth steel buckets (previously used) which have seen service with both an R20 and a GB72. The only issue I've had with these is shortly after swapping the R20 for a GB72 with a dodgy lobe....its case-hardening seem to have broken down resulting in a scored bucket ....like so.

Image

I replaced the damagd bucket with a brand-new cozzy one ..and haven't looked at the buckets since ... wow -just noticed that's 10 years ago :shock: (see photo date)

Foot note: when I used std bucket in a high revving engine it was with comp springs and hardened valve collets - AC told me the collets pulling through at high rpm was the major issue...also only used pukka machine shop shims - not DIY adjusted ones. Clan004
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Re: VAK 1972 Clan Crusader

Post by benwick3 » Tue Aug 28, 2018 10:07 am

As has been said I've used mixed standard buckets with no problems. I do, however, chamfer the leading edge as recommended by Andy Dawson.

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Re: VAK 1972 Clan Crusader

Post by bks974c » Tue Aug 28, 2018 7:16 pm

Thanks guys that's reassuring, I choose some standard ones that showed little sign of wear and chamfered the edges to match the others.

Scott
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Re: VAK 1972 Clan Crusader

Post by bks974c » Tue Aug 28, 2018 8:00 pm

Found the micrometer, where I first looked - on the bench but sitting in a folded magazine :oops:

Replaced the buckets and chamfered the edges to match the existing ones, the rechecked the clearances. Good news the exhaust was OK and the inlet a little tighter so with the found micrometer measured the shim and calculated I needed a 93 thou shim, pulled a shim from the box and by golly it's a 93 :D. Felt like I had won a medal :D

Bolted everything up and set about the cam timing, 135 thou at TDC no problem getting the phase right as it runs lost spark 8)
It took a couple of goes to get it spot on but thought I'd double check my figures as using a metric dial gauge - bother I was working to 3.3mm should have been 3.43mm so time to restart again. Balance once more restored to the universe :lol:

Loaded up the valve gear with engine assembly lube and refitted cam cover.
IMG_20180828_134534.jpg
Fitted a new spigot bearing, clutch plate and cover and bolted on the transaxle.
IMG_20180828_153134.jpg
Now fitted, ready to finish connecting everything tomorrow.

Scott
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Re: VAK 1972 Clan Crusader

Post by Lotus-e-Clan » Tue Aug 28, 2018 8:09 pm

Quick worker! Well done. 8)
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Re: VAK 1972 Clan Crusader

Post by bks974c » Wed Aug 29, 2018 9:39 pm

Reconnected the bits and bobs of the Clan, filled the oil cooler and pipes and primed the system via the oil pressure switch hole then spun it over with the plugs using a slave battery via the Anderson plug. Oil pressure came up quickly to 50psi :D

Now I was sure there were no issues with that side, I refitted the plugs, fuel system and exhaust and went for the restart - fired and ran instantly :D :D :D and I mean instantly :D

Now for the cooling system, topped up and started it again and the temp comes up quickly , too quickly so switched off and let it cool down then tried again. Its the same problem I had after fitting a new clutch a month ago, it's air locked but the system is well designed to self bleed but its not even flowing around the engine. Its running a 930 water pump so removed the temp sensor it has on the back (not used) and the air is expelled :shock: . Might modify it to include a bleed valve as that's twice now its been a problem.

Changed the wheels and got it back on the deck and drove it outside and loaded onto the trailer but there was a metallic clunk on changing gear :o. Took it home and after my tea unloaded it and went for a wee run or not, Motorway closed overnight and diversion route is our main road so turned around and went home. The clunk was still there and now I remember that the engine mount to body bolts are still to be tightened :oops:

As I'm loading the trailer with the green Octavia, Amy comes out to asks if I want a cuppa and says what you doing ? tell her I've brought the Clan home and taking the Octavia away and mention the loose bolts and quick as, she says you good at that :roll:
referring to the one and only time I left one of her sisters Sunbeam Sport wheels loose :lol: never going to be allowed to forget that one.

From the little I driven so far it seems very smooth and responsive, time to get it run in - after tightening the bolts :wink:

Scott
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Re: VAK 1972 Clan Crusader

Post by bks974c » Thu Aug 30, 2018 7:39 pm

Tightened the engine mounting bolts, added some fuel and took it for a run.

Water temp good, oil pressure excellent, pulls nicely with no issues but the clunk is still there - so not the mounting :(
clutch release bearing (vw roller type) a little noisy but it was before but didn't have another to hand - will order up a couple for stock.

Back home check it over and I think its coming from the diff either the Quaife ATB itself or excessive backlash :evil:

After tea took it for another loop, loving the engine, hate the knocking. Tomorrow going to drain the oil and remove the inspection plate and check it over.

Scott
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Re: VAK 1972 Clan Crusader

Post by Lotus-e-Clan » Thu Aug 30, 2018 8:05 pm

Always something niggly in one area to spoil the perfection found in another. :|

I know how you feel - I've loved the urge of the 1040 but have been annoyed by the release bearing 'clack' at idle. :x

But my stupidness has forced me to begin removing the engine today - which is half-out atm - all because I dislodged the clutch release roller bearing clips by pressing the rod into the slave in an attempt to clear sticky hydraulics! The roller housing has always 'clacked' at idle because it's too top heavy compared to the carbon race ..so once it's out I'll try a proper fix - maybe a retaining spring will stop it clacking?

Mind you I'm thinking of popping the spare 875 Sport engine in for a while so I can refresh the 1040 - it's been in the Clan for well over ten years and the valve guide clearances were at the edge of tolerance from the get go. I've put a few 1000 miles on it going up and down the A1 to Durham come rain or shine ...or snow! Part of me thinks the 875 Sport (with DHLAs) plus close ratio box would be a hoot - and part of me says don't be daft - fit the std box! :? But now my A1 commutes are history - back lanes beckon so keeping the CR box installed maybe not so daft! :D
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Re: VAK 1972 Clan Crusader

Post by bks974c » Fri Aug 31, 2018 8:17 am

Peter

Good luck with the engine change - do update your readers cars thread as it been a while

and we can do with a bit more content :D

Scott
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Re: VAK 1972 Clan Crusader

Post by Lotus-e-Clan » Fri Aug 31, 2018 11:39 am

OK will do. Charging up the SLR as I write ..don't have a smart phone! :)

A few things on JO J490N have changed which are probably worth posting-up in pictures: - rear lights - a complete change of style (inc sequential rear indicators). front lights - pod change again (still not normal -but more so than before). Electric 3-way valve in laminova cooling circuit - plus more front spoiler cut-outs for cooling. Front suspension stiffened and wheel arch liners added to rear to compliment rear floor aero-panels. Yep, s'pose there could be a bit of interesting content there -if only to take the p out of. :lol:
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Re: VAK 1972 Clan Crusader

Post by bks974c » Fri Aug 31, 2018 8:34 pm

Look forward to seeing the photos :D

Scott
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Re: VAK 1972 Clan Crusader

Post by bks974c » Fri Aug 31, 2018 9:30 pm

IMG_20180831_132559.jpg
After inspecting the diff via the inspection plate and not seeing anything definitive I decided to err on the side of caution as the box is rare and expensive and change it for a standard one - refurbed at the same time as the former.

Removing it went well having learnt a few things pulling it last time, such as removing the oil cooler along with the hoses means no oil lose. Transferred the ancillaries for the transaxle across taking the opportunity to change the CRB.
IMG_20180831_135337.jpg
Modified arm welded washers rather than clips
Getting it back in was problematic as I has chosen to do the work at the door as it was a lovely sunny day. however the floor slopes to a drain here which the issues with equipment rolling away, another pair of hands would have been handy but eventually got it in and fairly straight forward reattaching everything.
Bleed the waterpump so cooling system refill went better this time around.

Test drive time and the clutch bearing noise is gone :D however the clunk still there :?
Since its unlikely two gearboxes with the same problem it must lie else where, I'm thinking it has to be either the driveshaft UJ's although I inspected them on the car and all seems good and iirc the noise was there before the driveshaft but nowhere near as bad or the modified gearbox mounts :?

Tomorrow try changing the mounts for standard ones.

Scott
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Re: VAK 1972 Clan Crusader

Post by Lotus-e-Clan » Fri Aug 31, 2018 9:50 pm

I ran similar g'box mounts but reverted back to std because of noise transfer. The issue with mine was insufficient depth of rubber bush. It seemed to collapse under mounted weight and effectiveky made 'sonic contact' with its housing thus transferring noise directly va the rear crossmember into the shell.
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Re: VAK 1972 Clan Crusader

Post by bks974c » Fri Aug 31, 2018 10:19 pm

That sums it up nicely it sounds like metal to metal contact, I'm prepared and expect some extra NVH but not this level.

Scott
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Re: VAK 1972 Clan Crusader

Post by bks974c » Sat Sep 01, 2018 8:18 pm

Deviated from the plan :o I got the Clan up on axle stands and could replicate the noise by bringing the clutch up to biting point with the handbrake on and the whole car loaded up - drivers side rear dropped and n/s front rose up and when you depressed the clutch - bang.

You could see the doughnuts compressing and as they unwound you would get the noise which appeared to come from the diff area which convinced me that it was the modified driveshafts so changed them for a set of std sport shafts and comp couplings.
In my head I could even explain why :oops:

The result - exactly the same :( The positive side is I've ruled out two components.

Couldn't face getting it back on the axle stands to change the gearbox mounts so reattached the gutter trim that had come off at the National due to the heat and washed it ready for Bo'ness tomorrow.

I'll give the mounts a go sometime during the week.

Scott
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Re: VAK 1972 Clan Crusader

Post by bks974c » Wed Sep 05, 2018 7:21 pm

:D :D :D :D :D :D :D :D :D :D :D :D :D :D :D :D :D :D :D :D :D :D :D :D :D :D :D :D :D :D :D :D :D :D :D :D :D :D :D

Had a great day at Bo'ness on Sunday, weather stayed dry and plenty to see and do. Bumped into lots of people I knew and catching up took up some time. Even got a free lunch thanks to Shonah from Monklands Sporting Car Club who had a few members including Jamie her husband so she puts on a lovely spread for them. :D and being a member and regular competitor at their events I get invited :D

Today changed the gearbox mounts which has cured the metal to metal bang, when I removed them I could see witness marks on the crossmember where they were hitting :cry: . The comp mounts have a shaved down bolt head which unfortunately isn't enough, only solution is more clearance - how to achieve that is not easy as moving the engine and box backwards will affect the gear linkage and the change.

While the bang on changing has gone I can still feel and hear the engine and box moving, I guess with the extra power and torque the mounts are having a hard time keeping it under control so looks like an engine steady bar is on the cards.

Scott
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Re: VAK 1972 Clan Crusader

Post by Lotus-e-Clan » Wed Sep 05, 2018 7:56 pm

This was the problem with mine.

Are yours the same design?

Image
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Re: VAK 1972 Clan Crusader

Post by bks974c » Wed Sep 05, 2018 8:57 pm

Peter

Slightly different but same idea, will post up some pics.

Scott
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Re: VAK 1972 Clan Crusader

Post by bks974c » Sun Sep 09, 2018 6:02 pm

IMG_20180906_120033.jpg
IMG_20180906_120041.jpg
Peter

As you can see the issue with the crossmember bolts is not an issue as it uses a stud however instead of tapping the upper half it uses a bolt with the head reduced in thickness which is causing the issue when it contacts the crossmember.

Scott
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Re: VAK 1972 Clan Crusader

Post by Lotus-e-Clan » Sun Sep 09, 2018 6:12 pm

Aha!

We need a hybrid design of the two!

You've given me new hope for mine - replace the crossmember bolt for a stud like yours - then I guess I need to slot the crossmember mounting hole?

God knows why yours didn't have the bush bolt tapped? I got mine from moose a long time ago - before you got yours IIRC . They are a good idea but the design needs optimisation a tad.

Thanks for posting the pics - I wouldn't have thought about a stud solution otherwise! I've been stuck in a thinking rut! :lol:
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Re: VAK 1972 Clan Crusader

Post by bks974c » Sun Sep 09, 2018 6:25 pm

Yesterday had a further play with the engine mounts as I found the standard gearbox mount was just touching an addition crossmember mounting bolt which was causing the transfer of sound.

Moved the engine and box backwards away from the bolt head which brought the fan belt very close to the engine mount - infact after today's run to Scone it does touch but will address that problem next time the alternator is removed.

The result silence - well OK that's an exaggeration but so much better and a much more pleasant place to be. :D

Today we joined 15 Imps and a midget at Scone for the http://www.svtec.org/ show, another excellent day and able to hold a conversation on the trip.

Scott
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Re: VAK 1972 Clan Crusader

Post by moose » Tue Sep 11, 2018 6:32 am

Scott you have my MK2 design which looking at the pictures i have set you up to fail by assembling them the wrong way round! the tube is off set, the slimmed down bolt head needs to go to the short side of the tube, i will call you later to explain. So sorry about that but we can put it right, i have made another production change thanks to your feed back and use cap heads, so after out call i will sort you out some bolts. LEC if you want some improved mounts get in touch.


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Re: VAK 1972 Clan Crusader

Post by Lotus-e-Clan » Tue Sep 11, 2018 7:10 am

Ah I think I see what's happened now.

The carriers on my Mk1 design are thicker to allow tapping for the bush set screw - but the thicker-walled bush carrier affords too little clearance - hence my bush housing touched the carrier as they 'settled' in-service...hence very noisy so I swapped them for std mounts.

Scott's Mk2's have thinner-walled carriers (untapped) with more internal clearance than the Mk1 but are assembled the wrong way around so Scott will have had to assemble the bush on the crossmember with the off-set the wrong way around which has the knock-on effect of pushing the whole transaxle rearwards.

With the transaxle pushed backwards the driveshafts would be out of true too (not inline with the hub carriers!) If Scott didn't notice he might have had premature doughnut failure due to driveshaft misalignment fore and aft. I guess he noticed the transaxle displacement and the slotted crossmember mounting holes he cut allowed him to realign transaxle and the driveshafts (fore and aft) a tad?

I might have got that wrong though?

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Re: VAK 1972 Clan Crusader

Post by bks974c » Tue Sep 11, 2018 6:34 pm

Good to hear from you Mike, as soon as you mentioned the bolt being the wrong way round, looking back at the picture its obvious it should be the other way round unfortunately as it took the changing of the mounts to identify them as the source of the noise I never paid them too much attention before :o

Peter, the amount of adjustment is quite small so the impact on other components is pretty small probably little more than the standard amount available with the elongated hole in the crossmember.

Scott
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Re: VAK 1972 Clan Crusader

Post by bks974c » Wed Oct 03, 2018 6:16 pm

The Clan has been much nicer to drive without it's clangs and bangs so I entered the Clyde Valley Rally - a non competitive run of 130 miles, having done it a couple of years ago in the Green Clan some of the roads were very rough I made the decision to change the front springs.
20180925_170540.jpg
The originals were 8.5 inch x 170 lb/ft which could be a little bouncy on some surfaces so swapped for the ones originally on the Green Clan which I thought were 120 lb/ft but turned out to be 150lb/ft x 10.5 inches according to the label but they look much lighter than the originals.

Happy with the new stance as I have a PCT this Sunday so the raised height will be handy.
20180925_174613.jpg
The run went without issue covering just over 200 miles including travelling to and from the event - no water or oil used and 40 mpg not too shabby. The roads used were in much better condition than I was expecting and what rough bits there were the Clan glided over just like a Citroen OK that's an exaggeration but it coped admirably . Lunch halt was at Drumlarig Castle with you might recognise from Imp Ecosse.
20180930_124528.jpg
Scott
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Re: VAK 1972 Clan Crusader

Post by bks974c » Fri Oct 05, 2018 8:38 pm

Busy weekend ahead as I have an Autosolo at Errol between Perth and Dundee tomorrow and a Production Car Trial at Forrestburn on Sunday so time to prep the Clan.

First thing was an slightly annoying vibration that wasn't wheel balance as I had just fitted new tyres on different wheels and there is no play in any of the steering components so checked the wheels for run out, the n/s showed .7mm so checked the discs which showed run out, turned the disc around and the high spot was on the opposite side which point to the hub.

Found another hub and bearing and fitted that, refitted disc and checked again - negligible :D. Fitted wheel and run out now -.1mm/+.1mm That'll do thanks.

The O/S had less at .35mm however zero at the discs so its in the wheel so nothing I can do to change that but it's within acceptable limits . On the way how you can feel the IMProvement.

Swapped the rear wheels and tyres for a set with a more open tread pattern to suit Sunday, refitted the boot rack along with a couple of spare wheels. Originally I used the set I had just removed but they weren't heavy enough so dug out some standard 12 inch steels and connected them to the vacuum brake bleeder and sucked the air out then put the hose into a bowl of water and let it draw the water in. Nice and heavy now :o ideal for Sunday where it should help improve traction on the grassy hills.
20181005_172207.jpg
Washed the Clan and went home to take the wheels off the rack as not ideal for an Autosolo. All ready for tomorrow
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Re: VAK 1972 Clan Crusader

Post by bks974c » Sat Oct 06, 2018 9:21 pm

Cold start to the day but by the afternoon was down to a T-shirt ----------- plus trousers etc :lol:

Lovely day in the Sunshine, mixed performance from me biggest issue was the Clan jumping out of gear, don't believe its the box but the positioning of engine and box which are moving and pulling it out of gear. It's not something that has happened on the road and hope to sort it when I put the other transaxle back in before the next round on the 21st.

See last run of the day

When I got home washed the stoor off and loaded the spare wheels ready for tomorrow's PCT
20181006_181932.jpg
Scott
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Re: VAK 1972 Clan Crusader

Post by colimp66 » Sat Oct 06, 2018 9:28 pm

Looks like it went well Scott with plenty of stoor being kicked up.
Good luck tomorrow at Forrestburn. Keith was saying he is going too.
Col
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Re: VAK 1972 Clan Crusader

Post by bks974c » Sat Oct 06, 2018 9:35 pm

Definitely a lot more grunt with this engine and very driveable.

Yes we have 3 "Imps" Dave Charles is coming along too.

If your at a loose end pop along but you probably should be building an engine.

Scott
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Re: VAK 1972 Clan Crusader

Post by bks974c » Sun Oct 07, 2018 5:58 pm

What a difference today in the weather, yesterday was glorious sunshine today cold windy and rain - poor marshals.

Keith wasn't well so it was just Dave and myself up holding the "Imp" honours amongst a brace of MX5's/midgets/MGB's and a gaggle of vintage Austin Seven specials.

Not such an auspicious start on Hill 4 for myself, car seemed to struggle a little but cleaned it anyway and went to pull on the handbrake to get my card signed and it's still on :o :oops:

Oh well can only get better but the next Hill 1 I got a 2 with the handbrake off :roll:, Hill 2 nearly went very badly when I stalled it pulling up to the start but deemed to have not started yet, phew and went on to clean it. Hill 3 Clan bottomed out on something that seemed sore but ignored it and went on to score a 1.

Then on round again, Hill 4 was much easier this time around without the handbrake on, cleaned 1 straight over the top, Hill 2 sailed through for a zero, Hill 3 proving a challenge tried backing off a little that failed and got a 2 this time. So 5 for the morning.

After a barbecue lunch it was time to do it all again, however the weather has started to turn with the wind picking up and the rain becoming more persistent. First time round things are improving as cleaned all the hills but the rain is now really coming down (just getting the excuses set up :roll: :lol: ) Hill 4 slightly off line on the approach to the last steep section and with the ground now soaking failed to get traction and got a 1. Hill 1 got a Zero but only just ground getting slippery by the minute, Hill 2 cleaned it, Hill 3 got a 1 well I would have but touched a cane for a 3, all told 4 for the afternoon.

Took some video of Dave








Quite like the finish
20181007_1412041.jpg
Scott
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Re: VAK 1972 Clan Crusader

Post by bks974c » Mon Dec 31, 2018 8:21 pm

VAK has been rather ignored since the Nov PCT which I finished second again
See https://www.mscc.org.uk/sunny-silly-hat ... 1-2018.htm

Today replaced the dull blue led no. plate lights for bright white and fired it up :D

Scott
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Re: VAK 1972 Clan Crusader

Post by bks974c » Fri Jan 11, 2019 8:40 pm

Yesterday received an email from Knockhill about an Open day and trackday on the 20th, normally wouldn't bother going out in January but the weather has been so
unseasonably mild thought why not.

Today cleaned off all the mud and grass from the last PCT and lowered the car again while swapping wheels and tyres, painted the new engine steady bar and took it home.

Good to go but will change the oil before the event with some performance oil, also want to seal the side windows as the leak just a bit :?

However reserve the right to change my mind if its peeing down, fingers crossed the weather holds up. :lol:

Scott
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Re: VAK 1972 Clan Crusader

Post by Lotus-e-Clan » Fri Jan 11, 2019 8:54 pm

On the side windows ...Eric did a pretty good mod to his Turbo Clan.

He fiberglassed a recessed continuous lip around the inside of the apertures then screwed down poly carb replacement glass into the recess. The Poly carb is then aero-flush with the body. He used something like M3 counter-sunk allen screws (about one per 40 -50 mm IIRC) all around the aperture. The poly carb was seated within the recess using a bead of sealant on the recessed lip. The outside edges of the poly carb can be painted (if necess) to tidy-up the line of sealant visible through the poly carb.

He did the same to the rear glass and said the whole lot (bolted-in rear poly glass and poly side glass) actually added to the rigidity of the shell!

And it does look good too.

On my list of projects ... :) Clan004
74 Clan Crusader 1040 Red 190 bhp/ton
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