Karen's Imp Sport

Uncle Henry · Post by **Uncle Henry** » Tue May 10, 2022 8:43 am

Sorry for my ignoramus Scott, but what are "coming home lights" when they're at 'omega?

AG

The Nun · Post by **The Nun** » Tue May 10, 2022 8:49 am

Modern cars have them Andy the headlights stay on a timed delay when you lock the car up at night so you can see your way to the front door without tripping over the cat.

Uncle Henry · Post by **Uncle Henry** » Tue May 10, 2022 8:55 am

Ah, right. My modern has the "I'm over here, Dad" lights for finding it in the carpark, triggered by the remote. I dont have the luxury of a hard standing or drive, so wouldn't need the facility. Don't have cats anymore either, come to think of it

AG

bks974c · Post by **bks974c** » Tue May 10, 2022 9:17 am

Andy

We don't have any cats either but that doesn't stop the neighbours one from trying to get the birds and squirrels in ours, lights or not too bl***y quick to "trip" over it.

Scott

bks974c · Post by **bks974c** » Tue May 24, 2022 7:53 pm

Still playing with electric but need to move on and get it back on it's wheels before the end of the month.

To that end prep'd and painted some of the missing parts from the suspension.

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Scott

bks974c · Post by **bks974c** » Sun May 29, 2022 8:48 am

Suspension built up and on car, springs and shocks are temporary as still to be painted.

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Scott

bks974c · Post by **bks974c** » Sun May 29, 2022 8:17 pm

Karen's Sport off the spit and looking like a car again but not kidding myself how much remains to be done.

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Scott

Uncle Henry · Post by **Uncle Henry** » Mon May 30, 2022 9:44 am

Great progress, Scott, nevertheless.

UH

bks974c · Post by **bks974c** » Tue Aug 30, 2022 8:34 am

Now with the customers Stiletto ready to leave to go to his painter it's time to get back to Karen's Imp.
First job is to reskin the doors, the drivers side is the worst but pics are all of the passengers, doors stripped off all the internals and skins removed the put in the acid bath to clean up the rust.

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Found this in the door pocket, oh the good old days

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Scott

bks974c · Post by **bks974c** » Tue Aug 30, 2022 7:45 pm

Repairing the flanges on the inner door frame, window frame was quite wobbly as fair bit of corrosion where it fits to inner skin.

Gas finally ran out for mig, it's been running on empty for ages so no surprise.

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Scott

ImpManiac · Post by **ImpManiac** » Wed Aug 31, 2022 4:53 pm

Lovely work, Scott.

IM

bks974c · Post by **bks974c** » Sun Sep 04, 2022 8:39 pm

Last couple day's been away changing the rear diff on a Jaguar XJR but before that I finished stripping the outside of the bonnet, it looked almost perfect, paint spot on with only a couple of minor dents so I was tempted just to face off and repaint but me being me had to take it back to bare metal just to check.

Glad I did, although no rust there was a fair amount of filler on the nose of it and some pretty unsightly welds to the inner support - done by myself I might add but over 20 years ago, the fact that it hadn't rusted shows it was done well if a bit rough. 20 years later I have learnt a lot plus have a lot more tools and equipment so will redo the repairs and future proof it.

First task was to remove the return and the front edge and then the reinforcing section, inside of the skin is in quite remarkable condition with almost no rust, in fact the outside shows more pitting. Repair sections made up and welded in, tomorrow I'll start on the outer skin.

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Scott

Uncle Henry · Post by **Uncle Henry** » Mon Sep 05, 2022 10:14 am

Nice job, Scott. I recently had mine blasted so the true condition could be seen, then Colin Rooney cut out the bad sections and let new metal into it. I skimmed it over and its pretty fair to be honest. At least rust free now and treated with Bilt Hamber stuff. I'd still be tempted by a brand new one though, if Expressed ever find enough interest to make new ones.

AG

bks974c · Post by **bks974c** » Mon Sep 05, 2022 9:07 pm

The shapes and angles are fairly subtle in an Imp, very few straight line, taking the bonnet front edge not only does it come to a point at the front it also sweeps up at the bottom edge - all fun when making replacement sections.

Not quite finished the repairs to the outer skin, the n/s front corner needed more work than I was expecting but good progress anyway.

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Scott

bks974c · Post by **bks974c** » Tue Sep 06, 2022 9:25 pm

Finished up the repair to the front of the bonnet, tomorrow strip the paint at the rear where it looks like it was repaired previously.

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Scott

colimp66 · Post by **colimp66** » Wed Sep 07, 2022 9:01 am

Very tidy Scott, That will last another 50 years now

Cheers
Col.

bks974c · Post by **bks974c** » Wed Sep 07, 2022 9:55 pm

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colimp66 · Post by **colimp66** » Thu Sep 08, 2022 9:15 am

Is that extra bracing on the doors Scott with the box section?
Coming from the hinges to the rear of the door at the lock area? Not standard so I'm assuming you put that in when you restored the car the first time?

Good idea.

Cheers
Col.

bks974c · Post by **bks974c** » Thu Sep 08, 2022 6:38 pm

Hi Col

Yes, one of the many mods I did to make it safer, able to finish welding them in now

Scott

bks974c · Post by **bks974c** » Thu Sep 08, 2022 7:36 pm

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Scott

bks974c · Post by **bks974c** » Sat Sep 10, 2022 11:21 pm

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Scott

John A Ross · Post by **John A Ross** » Sun Sep 11, 2022 6:53 pm

good shout on the door mirror position

bks974c · Post by **bks974c** » Sat Sep 24, 2022 9:35 pm

Hinges were too worn to use the 6.5mm oversized pins I have and need 2nd over size at 6.75mm, I ordered them and a suitable reamer before I left for the Wicked Welsh and they were there when I got home, except the reamer was undersized although correctly marked meaning I had to order another which arrived this morning.

After reaming the hinges out and fitting the new pins hung the n/s door, I knew the Expressed Door skins were the wrong shape at the top edges and hadn't folded it over initially. A bit of trimming and welding had them fitting well along with a bit of spacing of the bottom hinge the swage line aligned well. Tightened the gap at the front edge by welding in welding rods, more work tomorrow but looking Ok.

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Scott

bks974c · Post by **bks974c** » Sun Sep 25, 2022 10:06 pm

O/S door pretty much a repeat of the other side but need more welding rods to complete

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Scott

bks974c · Post by **bks974c** » Sun Oct 16, 2022 9:42 pm

After too many hours to mention finally into primer.

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Scott

Pog · Post by **Pog** » Mon Oct 17, 2022 4:16 pm

Really coming together now, Scott! You posted when you resurrected this thread the deadline was Oct 2022, 2 weeks to get it done! Loads of time right

Pog

bks974c · Post by **bks974c** » Mon Oct 17, 2022 4:32 pm

Pog wrote: ↑Mon Oct 17, 2022 4:16 pm Really coming together now, Scott! You posted when you resurrected this thread the deadline was Oct 2022, 2 weeks to get it done! Loads of time right

Pog

No, another deadline missed but it's nearly wintertime so it would be off the road anyway

. Plan is to continue until it's painted then get on with paid work and try to refit it alongside.

Hard deadline is spring next year so Karen can use it for the "dry" seasons.

Scott

Uncle Henry · Post by **Uncle Henry** » Tue Oct 18, 2022 8:28 am

Unfortunately, sometimes life gets in the way ! We all get things popping up that take away the good intentions. It will get done, I'm certain. Looking good anyway, Scott.

UH.

bks974c · Post by **bks974c** » Tue Nov 15, 2022 4:57 pm

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Hopefully the penultimate coat of primer and this blocks out OK.

Scott

Pog · Post by **Pog** » Fri Nov 18, 2022 11:49 am

Proper jealous of your workspace Scott! All looking superb, can't wait to see it in final colour

Pog

bks974c · Post by **bks974c** » Mon Nov 21, 2022 9:47 pm

Unfortunately, did not fully block out and required some more work on the passenger front wing, that's been done reprimed and blocked out Again.

Today put on hopefully the last coat of primer, tomorrow start blocking out with 600, all rubbing down done dry although slower and messier that doing it wet it avoids the issues of moisture in the paint layers.

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Scott

moose · Post by **moose** » Wed Nov 23, 2022 6:29 am

It will be worth it when done Scott.

colimp66 · Post by **colimp66** » Wed Nov 23, 2022 9:20 am

It's all the little details that take the time and no point in rushing it now Scott

m sure it will be ready for Ecosse or the the National for next year.

Cheers
Col.

bks974c · Post by **bks974c** » Fri Dec 02, 2022 10:10 pm

Progress was slowed down as I tried to sort my Mum's Fabia whose Alarm was going off as well as locking and unlocking randomly, initially changed the driver's door lock which had shown an issue when scanned of indicating it was open,when in fact it was closed. After much chasing replaced the window motor which although working fully sorted the problem, the key switch signal passes through the window motor which has it's own printed circuit and software incorporated into the assembly. They are great when they work but a real pain when they go wrong not like Imps which never let you down

.

Anyhoo, progress after a couple of days of cleaning down the booth (that's what you get for using it for all sorts of work) finally got some colour on the inside of a couple of panels.

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Scott

Uncle Henry · Post by **Uncle Henry** » Sat Dec 03, 2022 9:54 am

Modern cars eh ? A good friends daughters Vauxhall firstly developed an indicator lamp that came on, stayed on and refused to clear no matter what. A replacement flasher unit was fitted, and the problem remained. On line he was advised that the drivers door lock might be to blame. Cue replacing that too, and to no avail. Next came the main ECU. No longer available and rare secondhand. Sent off for repair (wasn't possible), so eventually cloned to a known good one, and the car is now fine again. But what a palarva ! You don't get this with old cars where the logic is, well, logical ! It's simple to trace, whereas on modern cars every ecu talks to its neighbour and has to have permission from the Boss ecu to work. Progress ? Not in my book. My old Rover 600 ti used to fire up the twin radiator fans if the battery was near flat, I guess in order to finish the job off !

UH

bks974c · Post by **bks974c** » Tue Dec 06, 2022 10:51 pm

After another couple of days finishing off bits that I thought I had finished

Once you're cleaning up ready for paint it's amazing the things you hadn't seen previously.

So this morning faced back the areas I that needed work and had primed yesterday, final clean down and started painting - 3 coats of basecoat and 3 of clearcoat. Previously I have flatted back and then polished for the final finish but taking a different approach this time, going to face it off with 800 wet and the apply another coat of clear and then call it a day, hopefully.

Another thing I did different this time was to lay the boot lid and bonnet in place applying the basecoat so that the metallic flakes lay the same way as the adjacent panels, that also the reason the doors were on the car. I then clearcoated them off the car as the edges around them needed done.

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Scott

jetmech · Post by **jetmech** » Tue Dec 06, 2022 11:45 pm

Excellent work.

Simon

bks974c · Post by **bks974c** » Wed Dec 07, 2022 9:10 pm

Before starting to face off the Sport I refitted the boot/bonnet and door catches to save any accidents where they may get knocked over.

One of the mods I have done is fit adjustable bump stops for the engine lid as they never seem to sit level using the original ones, they needed slimmed down so they miss the return edge but it fits properly now.

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Scott

impmann · Post by **impmann** » Mon Dec 12, 2022 10:29 am

I like the bump stops - where did you get them from?

moose · Post by **moose** » Mon Dec 12, 2022 5:02 pm

https://www.eastkenttrimsupplies.com/fo ... 2x17950430 I am guessing here as Scott is skillful enough to make his own version. These were used on clans but with a longer bolt I think.

bks974c · Post by **bks974c** » Mon Dec 12, 2022 6:18 pm

https://www.ebay.co.uk/itm/275440604102

Much better price

Happy to sell the spare ones at East Kent prices if anyone needs some.

Scott

bks974c · Post by **bks974c** » Fri Dec 16, 2022 9:10 pm

This week it's been too cold to be painting so I've been messing about with modifying bits that have to go back on after painting.

The first thing I decided to IMProve was the steering column, the top bush never seemed like a great solution; I felt a proper roller bearing would be much better. I had a trawl around for one that fitted both the inside and outside but never found one, however I found a needle roller that fitted the inner shaft and a bush that fitted both. As expected the bearing was a little loose on the bush so I had welded on a couple of nuts ready to hold a couple of grub screw and pinch the bush, worked out lovely

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Since the rack is attached to the column that was next, after checking what was available I stripped it noting that the pinion bearing was notchy due to water ingress and the bush at the other end was well worn allowing a lot of play. Ordered the bits from Bob at Club Spares but advised that the bush was a metric equivalent so would have a bit of play, I opted to grab a spare rack and strip that, the bush in that was much better so will rebuild that one, currently waiting on the parts to be delivered.

Moved onto the gearbox, which is the original box from the Sport and known to be in good order, just replace the seals. I had the seals in stock but not the o-ring on the selector shaft so added that to the parts list. What was surprising was the reverse gears, they are always "damaged" where they mesh but these are mint. Karen must be a sympathetic driver.

Time to look at the engine, this is not the final unit that will be fitted, the original to the car is with Andy Jones being rebored +20" and fitted with a crank oil seal. On initial inspection the crank looked good to go and just require new shells, the head was refurbished with new guides and valves with the last batch of engines I got done.
Time to finish off the engine management, first to attend to was the engine harness, replaced the injector plugs and wrapped the wiring.

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Not happy with the fuel rail as it wasn't straight where it had been cut and spaced out, so ground off the weld and rewelded.

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Finally had a go at the air filter box, wanted to fit a K&N filter as standard Sport ones getting harder to find and expensive although still have some stocks. Had a search by size to find something suitable, ended up going for Triumph bike one, hopefully it fits. In the meantime I started modifying the lower housing by making up an adaptor to hold the filter, will cut the hole when I have it in hand.
Altered the top half by adding Sporty twin inlet pipes, I used 22mm copper pipe as had that to hand. I would have liked to have gone big bore and gone to 28mm but wasn't going to go and buy some.

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Scott

Uncle Henry · Post by **Uncle Henry** » Sat Dec 17, 2022 9:39 am

Great work Scott. Somewhere along the line I've missed the fuel injection stage !

I'd better search that out if it's still available. I too was concerned about Sport air filters becoming rarer, but went a slightly different route, involving motorcycle inlet trumpets (bell mouths as we used to call them), a modified airbox inlet tube, silicon hose and K&N style cotton filter.

UH

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bks974c · Post by **bks974c** » Sat Dec 17, 2022 4:59 pm

Nicely done, Andy.

I want Karen's to look "standard" with just enough changes to force anyone looking at it to take a second look to see what's different, part of the reason I went for modifying the twin Stromberg Manifold rather swapping for a ready made system created a lot more work but I'm happy playing around.

Scott

bks974c · Post by **bks974c** » Sat Dec 17, 2022 5:26 pm

Removed the engine that will be used for initial mapping, rather than messing up a newly rebuild one, off the test stand then went looking through the old clutches for a useable one. Discounted the QH one as they tend to be heavy and the one recently removed from the Clan as it had a rattly thrust pad that left two, went for the cleanest along with the plate with the least wear.

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Had a look at the exhaust manifold and gasket to see how the port holes matched, not good, not enough material to seal properly

Anyway have a used competition one at home so I'll use that initially and get some new one when I fit the original engine.

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Painted the coil and TDc sensor bracket.

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Scott

The Nun · Post by **The Nun** » Sat Dec 17, 2022 6:48 pm

That's not a sport manifold gasket though.
Club sells the sport ones.

bks974c · Post by **bks974c** » Sat Dec 17, 2022 8:32 pm

The Nun wrote: ↑Sat Dec 17, 2022 6:48 pm That's not a sport manifold gasket though.
Club sells the sport ones.

Peter

What's the different with the Sport ones ?

I have other gaskets - non-metallic but dimensionally identical that I think might be Sport ones ? They have the same issues

The issue might be it's not a Sport manifold but a stainless steel one bought from the Clan Club many years ago and still in excellent condition, thought it expensive at the time £350 iirc (including silencer) but it's lasted well

. The bores appear to be a bit bigger and the edges of the holes not totally flat where the pipes have been welded to the flange.

Scott

The Nun · Post by **The Nun** » Mon Dec 19, 2022 12:04 pm

The sport gaskets are the non metallic ones like a matt grey sheen colour , I've recently fitted one and it fits perfectly, however it just could have an old stock Rootes original thinking about it so it would fit of course.

bks974c · Post by **bks974c** » Mon Dec 19, 2022 7:51 pm

Today was a big change in the temperature, forecast was for a max of 13, so time for paint

When I flatted back the Imp I rubbed through in a number of spots all on the passenger side, can only think I was a bit light on the clearcoat along that side. Karen was up and thought that it had more sparkle to it originally

so I decided to repaint it

, if the basecoat was put on a bit wet it causes the flakes to lie flat. This time it was put on drier and lighter so the flakes stand on their edge and reflect the light then re lacquered with extra coats - really don't want to rub through again.

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Scott

John A Ross · Post by **John A Ross** » Mon Dec 19, 2022 8:13 pm

Lovely work Scott

Fancy a body/paint challenge in black