FHC resto nr. 170; Fitting the steering column

Another job that needed redoing was coating the steering column’s outer tube. Actually I had to find a spare one as the original item that was powder coated got seriously distorted in the process. And with only one part to do I decided on a traditional line of approach: Cleaning the dirt from the tube and bead blasting it. After which I used primer and satin black paint from rattle-cans to coat it. Looks quite good for a piece that will be completely hidden from view!

Next stage was rather straightforward; fitting the two new steering column bearing bushes to both ends of the tube and adding the steering shaft to the outer tube. Decided to use a silicon based bearing grease as lubricant between the bushes and the steering shaft. Feels quite tight but also very smooth. Will see ones the car is back on the road!

Final jobs were fitting the steering/ignition lock and fitting everything to the car. Though while fitting the lock mechanism to the outer tube I found out that I prepared four Allen head bolts with an incorrect thread to replace the original shear bolts. I thought they were metric M8. But they were 5/16”. First idea was to drill out the holes and use a metric thread repair to get the necessary M8 thread. But I decided to try out a little bodge first. Changing the 5/16” thread with a M8 tap. The result was actually far better than expected, with smooth threads. And I could even torque down the bolts pretty tight without stripping the new threads. And much tighter compared with the original shear bolts which still had their shear heads in place. So more than good enough for a non-structural part!

The two M10 Allen head bolts, I prepared for mounting the steering column to the support rail, were a perfect fit. So no issues there.

FHC resto nr. 163; Spreading the load

Or strengthening the rear of the armrest. With the facia switch panel back to its former glory, it was time to switch my attention to the rear of the interior. The Armrest to be precise. For those who have owned or worked on a TR7 that has had a hard life (read careless or incompetent owners) will know that the armrest mounting points can suffer. And all armrests in my spares collection had suffered! Luckily there was one item with only minor damage. But better safe than sorry. So I decided to fabricate a few small steel plates to go over the affected areas. The idea behind it being, that by spreading the load over a larger area, the mounting points will be more stable and further damage will be prevented.

The first stage of the job at hand was measuring the dimensions of the affected areas and putting them in a digital format.

This was than printed out in full size on paper, cut out and glued to some left over 1.30mm thick steel pieces (see picture above), to act as pattern for cutting and drilling. This gave me these three pieces (see pictures below). The first picture was taken after cutting the pieces from the steel left overs, with the remains of the pattern paper still in place. The bottom picture was taken after the paper and glue was burned away with a gas torch and the edges were finished with a grinding wheel.

And in their designed position, after adding a bit of black paint from a rattle can:

Trial fitting the two plates to strengthen the mounting points to the rear bulkhead.
One plate needs to be flipped through 180° in the picture above,
when the arm rest will be fitted to the car.

And the strengthening plate for the mounting area

where the arm rest lid is fitted to the cubby box.

FHC resto nr. 155; 10 Years into the project

The coming week (on October the 17th to be precise) it is exactly 10 years ago that I purchased my last TR7. A pretty early Dutch FHC which was first registered on the 6th of October 1976. It left the factory clad in a Pimento Red (CAB) coat of paint and was fitted with a black cord (CPAA) cloth interior.

I actually stumbled upon the advert for this car while I was doing my periodic internet search for a set of Wolfrace Turbo wheels for my DHC. The rest is history as they say!

2013-10-12 After a short test drive to get an indication of the cars mechanical parts,

before agreeing on the actual purchase;

The original plan was to give it a proper service, a few repairs where necessary, a fresh MOT, and sell it on minus the Wolfrace wheels. But I was never any good at selling cars. And I have always been longing for an early Dutch registered Speke built TR7. Mainly because I really have come to like the clean lines of the early bonnet design.

So I decided to restore it to a more or less standard looking car, with a few (reversible) period detail changes incorporated in the process. And the schedule wasn’t too ambitious either! It should be completed by the time the car became tax exempt some three years later.

Sadly life (and death) intervened several times in the past years. As a result of which the car is still not finished 10 years on! Though I am getting there slowly but surely. At least this 10 year “jubilee” gave me an excuse to trawl through the well over 2000 digital pictures shot so far during the restoration. And post this pictorial summary of the work done so far. In chronological order;

2014-01-29 Removal of the engine while dismantling the car,

in preparation for the body repairs;

2014-02-12 The empty shell remaining after dismantling of the car was completed;

2014-03-15 While the body was away for paint removal and shot blasting,

I started on various parts needed in future. The rear suspension in this case;

2014-03-29 The drivers footwell after shot blasting;

2014-03-29 The left hand front inner wing area after shot blasting;

2014-03-30 Another part that arrived well ahead of schedule;

a slightly customised 14” Moto Lita MK4 steering wheel;

2014-05-24 Reconstructing the incorrect small fuel filler rear deck,

and the heavily butchered boot floor;

2014-05-28 Rear deck and boot area finished;

2014-06-11 Adjusting the left hand door gaps;

2014-06-25 Repairs on the right hand inner front wing area;

2014-07-10 Welding finished and waiting for final shot blasting

and coating with a primer;

2014-07-30 The refurbished seats covered in a specially woven red/black McBeans tartan;

2014-07-30 Recovered GRP parcel shelf;

2014-08-20 One of the repaired doors after returning from E-coating;

2014-09-09 Traditional paint preparations, filling and smoothing the roof;

2014-10-11 The car’s chosen colour combo;

2014-12-11 Nearly ready for painting;

2015-01-10 Applying the anti-chip coating to the body’s

underside in preparation for painting;

2015-01-19 Ready for painting bottom and inside;

2015-02-05 After the first visit to the painters. The interior, the engine bay

and the underside painted in lovely and bright “Nearly-Topaz-Orange”;

I have since found out that RAL2000 Yellow orange is a pretty close match.

2015-06-12 Home made striping and decals ready for application;

2015-06-13 The body, doors, boot lid and bonnet are ready for painting;

2015-09-08 Painted in its chosen colour at last, and waiting for the

satin black paint to be applied to the sills and the rear light panel;

2015-09-14 Back in the shed in lovely “Nearly Topaz Orange”;

2015-12-22 Fitting the sound deadening (or anti resonance) pads to the interior;

2016-01-09 The original VIN plate and body tags,

clearly not fit to be reused on a fully restored car!

2016-01-14 One of the little projects that got out of hand a little, especially time wise.

Remanufacturing the body tags (with a twist) and the VIN plate.

The joys of modern software and online remanufacturing possibilities;

2017-05-10 The refurbished early Speke model throttle pedal;

2017-05-21 The refurbished parts for the pedal box, plus a few new ones;

2017-06-03 The inside of the newly coated fuel tank;

2017-12-20 The small parts shot blasted in preparation for plating;

2018-01-04 The small parts after zinc plating and (black) passivating;

2018-01-10 Refurbished gear box extension;

2018-03-31 The end of an era and a sad farewell. Clearing out the shed at René’s premises,

after he passed away. It was also the first time I saw the body outside in bright sunshine.

It did cheer me up a little;

2018-09-14 The refurbished head lamp supports;

2018-10-06 Fuel tank and fuel filler neck in position;

2019-01-06: Refurbished parts for the boot lid lock mechanism;

2019-03-23 Pedals and refurbished heater fitted;

2019-12-08 Refurbished parts for the door handles and ignition lock;

2020-02-27 Modern aftermarket (Volvo/BMW) brake light switch fitted;

2020-02-29 Fitting a few exterior trim parts;

2020-03-15 The new heart for the car, a NOS Sprint short engine

(with Mahle pistons!) and cylinder head;

2020-05-09 Adapted Allen head bolts for mounting the ignition switch;

2020-06-01 Cleaning and detailing the front side lamp lenses;

2020-09-23 Spot the problem! A water pump cover that escaped British Leyland’s quality control!

Needles to say I opened up the blocked passage leading to the radiator

2020-09-24 Refurbished water pump cover and a very rare original TR7 Sprint water transfer housing.

And yes the blocked opening of the pump cover was opened up;

2020-09-29 Fitting the homemade decals to the boot lid;

2020-09-27 And fitting part of the striping to the sides of the car;

2020-12-06 The refurbished front side lamp units;

2020-12-12 The side lamps fitted to the front bumper;

2020-12-19 Detail of the striping on the front wing and bonnet area;

2020-12-19 The striping running along the left hand side of the car;

2021-02-13 In the shed and the winter Sun just catching the vibrant paint work;

2021-05-10 Remanufactured alloy 5-speed shift pattern on the gear lever knob;

2021-05-13 Completed Sprint/SU inlet manifold, including my own design

alloy carburettor mounts and insulation spacers;

2021-07-06 Detail of the home made nose decal;

2021-11-13 Close up of the early type bonnet safety hooks;

2021-11-13 Brake balance valve and cunifer brake pipes;

2021-12-24 Remanufacturing the brake pipes for the back axle

using conifer pipe (top is the original);

2022-01-07 Locally fabricated stainless flexible brake hoses;

2022-01-08 Fitting the brake pipe running from the brake balance valve to the back axle;

2022-07-31 Refurbishing the engine harness (RKC 5511);

2022-09-28 Refurbishing the main harness (PKC 1946)

2023-01-21 Notes to help me refitting all the wires in

the correct order in the various connector blocks;

2023-02-22 The refurbished fuse box in the main harness (PKC 1946)

2023-05-20 The main harness in position, seen through

the opening for the right hand head lamp pod;

2023-10-08 Original pattern remanufactured door seals fitted;

Looking back over the past 10 years there have been a fair amount of ups and downs. But overall I am well pleased with the work done so far. And stating the obvious; I’m really looking forward to get the finished product back on the road. And that moment is slowly but surely drawing near!