This page has pictures covering the initial set up and strip down of the donor car.
I bought the donor car in November 1997
a Ford Granada 2.8i Automatic,
having already paid my deposit and confirmed my order for the Sabre. I
had been looking for a number of weeks at both damaged and usable cars
and finally came to buy one in a private sale. Like many people before
me what you believe you are getting is not always the case.
This car seemed tidy enough for the year without to many knocks,
rumbles
or groans from any of the mechanical parts. In fairness nothing to
drastic
occurred whilst I was using it, which I purposely did to see if there
was
anything wrong prior to the strip down. Once the engine was out it was
clear that it hadn't seen a service for a considerable time...if ever!!
Someone had also decided to include in with the oil an additive, I
assume
to reduce noise, which had turned into a solid mass....impossible to
work
with, so it was fortunate that I had intended to complete a full strip
down and rebuild of the engine, more importantly it had been budgeted
for!!!
I ran the car for
2 months and decided to start stripping it down in the
January, getting Christmas out of the way. The Sabre kit had a
provisional
pick up date of March and I was keen to give myself enough time to get
everything ready. One problem that I knew I would come up against was
the
size of my garage! Its not exactly large, with no room to get in or out
once the Granada was in! I had to plan in advance all of the activities
required in the build so that I could establish whether they could be
done
inside or out....fortunately I have very amenable neighbours and an
area
at the side of the house that was acceptable to use. So far all has
gone
well..... I can use the garage with the car inside but the wings need
to
remain off, not a problem until the very last stages. I duly picked up
the Sabre kit on March 18th 1998 debating with my friend on the return
trip where I was going to put everything! Although I had spoken to
numerous
people about the build, the size of chassis and the body parts there
seemed
to be far more than I imagined...after pacifying my wife I secured an
area
at the rear of the garage.
It was evident that with the poor weather during January and February I
had not progressed as far as I should have with the strip down. The
discussions
with my wife were generally of the nature 'when will that old car be
off
my driveway' to which the stock response was ' won't be long now dear!
' In fairness my wife has been extremely supportive of the time I have
spent on the car and I'm sure things could have been considerably
worse!
I would suggest that any body contemplating building a kit records as
much
information as possible about the hours they work, the parts and costs
involved as this all builds up to complete the overall record and is
good
historical information to keep with the car. I have an Excel
spreadsheet
that I use, recording hours by week, costs etc. It makes good reading
alongside
my original budget!!
Whilst stripping the engine I found that the air intake pipe from the
air flow meter had been split and had caused some problems within the
plenum
chamber, this was stripped and cleaned ( the photo shows how the right
hand air intake is full of muck compared to the left) After partly
stripping
down the car I set about the rebuild of the engine. I wanted to
complete
this first so that I could test it as soon as possible in the car and I
did not want to stop the build half way through to put the engine
right.
After spending an afternoon cleaning the muck and grime off the
exterior
of the block I wished somebody had told me to have the engine steam
cleaned
prior to it's removal! It would have saved much time and I would have
had
clean overalls! I stripped down the block and took it away for
degreasing
and reboring. At the same time I replaced all bearings, valves, guides
etc. I also had the rocker covers, plenum chamber and accelerator
housing
cover polished at great expense! But I think the end result was worth
it.
I replaced the normal Fuel Pressure Regulator with a Power Boost model,
used Bosch 4 spark plugs and renewed the distributor cap, coil
and
all leads.
Having stripped and rebuilt engines in my youth I was familiar with the
general mechanics of the engine, so I didn't encounter to many
problems,
although fuel injection was new to me. I had decided some time earlier
that I wanted full dial instrumentation and quickly learnt that this
meant
a move away from the electrical movements and onto mechanical. I didn't
realise how time consuming the process would be in finding the various
adapters that were required, especially as I wanted oil pressure, oil
temperature
and water temperature, the number of discussions that I have had with
adapter
suppliers doesn't bare thought and if any body wants to save themselves
some time send me an email.
I also wanted to use stainless steel hose coverings and end adapters to
finish off the engine but after(!) spending a considerable sum on parts
and then being totally dissatisfied by the result I gave up and went
back
to conventional hose. On this point I would advise against purchasing
hoses
etc. in advance, as I did. These are expensive items and because of the
slightly different layout of the engine bay stock items don't always
fit.
An example of this are the air flow meters to intake hoses which
because
of their large size are quite expensive. I found I could not use either
of these due to the repositioning of the meters and air filters....you
have been warned!
The final picture in this gallery shows the engine in all its glory
albeit
somewhat undressed without all its ancillary components attached. The
first
phase was now complete and I could look forward to the build itself!!
Overall
I spent more than 50 hours on the engine and some 88 in stripping down
the car, labelling and storing all the components just to get ready for
the build! The donor finally went to heaven in November 1998 and cost
me
£10! Much to the amusement of my wife!!