End of season - To-Do list

Getting towards the end of the good weather and driving season with a certain autumn feel now in the air. I'm starting to compile the winter to-do list. Some are already started with parts ordered and just waiting for enough bad-weather that dash/off is unlikely to remove any driving opportunity:

1. Intercom II

The new intercom approach, financed by a little selling on eBay, is a combined shooting ear-muff + motorcycle bluetooth intercom hack. Intended to avoid shouting between driver and passenger. The radio will also have a simple Bluetooth transmitter added.

2. USB Power

Replacing the existing single 'lighter socket' with a couple of purpose built twin USB power outlets

The front socket is permanently used for camera and sat-nav anyway.

3. Aux Panel buttons upgrade

The savage switches will be coming out to be replaced by something more robust.

4. Suspension height + brake disc paint.

That feeling when the seat bolts bottom out on roads with a high camber needs correcting with a turn on the rear adjustable coil-overs to stiffen things up a little. It's probably a combination of the springs settling and me getting heavier - or driving faster :) . I think I'll paint the slightly rusty/visible parts of the brake discs while the wheels are off.

5. Wideband Lambda

Some discussion on Facebook + identification of a new (to me) piece of Wideband lambda kit. It can null out some inaccuracies caused by installation, loom driven voltage variances, and looks interesting. Intending to swap out the narrowband (parts not yet purchased for this one)

6. Clocks surround + Shift light
I must get around to removing the stainless clocks surround and changing the mirror finish. I think just a brushed one will do the trick and stop it reflecting the sun right into my eyes. This post on Mitch's Blog reminded me. Installing a combination shift light and indicator tale-tale while the dash is apart.

None are must haves - just tinkering/upgrading.

That should keep me busy!

Silencer refurbished, re-installed and back to nominal performance

GBS did a good job on the silencer.

Keith confirmed over the phone they could sort it out so I took it up last weekend, had a chat with Richard, handed over the offending item and meandered back through Lincolnshire. 

Got to have a wander around my namesake City - Lincoln, it's Cathedral and medieval quarter.

The refurbished silencer was back on my doorstep by Wednesday!

The silencer rear end cap had been removed, interior pipe re-worked, wadding re-packed, re-assembled and cleaned into the bargain.

Re installed on the car today: new exhaust gasket, manifold, lambda probe re-installed and then the silencer. This time no exhaust jointing compound - 1. because it was so hard to part last time 2. the old tube of the stuff had gone off.

I replaced the rear bracket padding - the old pad was made from fuel pipe offcut which must have lasted 10k miles now - a little worse for wear but seems to work so replaced it with the same thing.

Quick run to my parents - around 70 mile round trip to test.
Everything back as it should be - engine and exhaust sounds & no rattle at any rev range, power or idling.

15100 miles on the clock - lets see how long she stays like it this time.

Running repairs - Silencer

The silencer has developed a nasty rattle around 2,000-2,300rpm, and on overrun, first noticed it on the Barcelona run last year.

Finally got to the point where I have had enough and it needs to be resolved permanently.

Spot the missing item from the left hand side of my Zero:

The manifold had to come off too - there was just no budging the manifold/silencer joint on the car, or even off the car.

After lots of advice from the RhoCar club on possibly approaches - '2b cruising'  helped out. Application of two pairs of hands, rubber mallets, gravity, heat and brute force did the trick - silencer now separated from the manifold and no damage done.

Next step is to return the silencer to the supplier to see what they can do.