"Cleanest MG in Ireland" ZS Restoration project

[LukeZS96]

So I've decided to take the ZS off the road when the NCT runs out in January and complete a full restoration.
Here she was when I first got her back in August 2014:
http://i1276.photobucket.com/albums/y471/lukedorney/Mobile%20Uploads/FB_IMG_1476218959240_zpseh8f368b.jpg (http://s1276.photobucket.com/user/lukedorney/media/Mobile%20Uploads/FB_IMG_1476218959240_zpseh8f368b.jpg.html)


And how she sits now:
http://i1276.photobucket.com/albums/y471/lukedorney/14117692_1264721140206967_3514771657340777178_n_zp szctnzn5g.jpg (http://s1276.photobucket.com/user/lukedorney/media/14117692_1264721140206967_3514771657340777178_n_zp szctnzn5g.jpg.html)


Plans are:
Any rust in the chassis to be cut out/ground back and the whole chassis to be undersealed.

Any paint work blemishes to be repaired (possible full body respray I'll get it machine polished and go from there)

Black oak Dashboard and (if I can get my hands on them) Black oak PPD door cards

Alcantara interior with the MG logo stitched into the headrests

Head light restoration (DONE)

Boot spoiler fitted (Done)

Front Foglights (Done)

Fit HID headlight bulbs (possibly get a custom made projector light units)

Fit Chrome kickplates

General PPD interior and then a few other miscellaneous jobs to generally improve the car

And then there's the biggest part of it all, I'm taking out the little 1.4 K-series and doing a T-16 turbo conversion.

So that is all for the minute, I have a few of the smaller (and cheaper) jobs done and I will upload the pictures whenever I get photobucket working properly for me. I will be using the car as a daily driver until I can get myself a nice ZR then the old girl will be driven into the shed and wont see the road until all the above work is carried out. My goal is to have this done for the 15th anniversary of MG-R going bust and whatever commemoration show coincides with that will be her first outing. I will keep this thread updated as much as possible and will be using this forum to keep my arse in gear on the days where motivation drops off.

Watch this space.
:mbounce:

[peterzs]

Good Luck, plenty of pics, as you go along.

:):):)

[daytona365]

Sounds good, Id love to do that with mine..

[Deckz]

Removing the 1.4 and replacing it with a T16 sounds good :)

[LukeZS96]

So high time I gave this thread a quick update now that I have photobucket working again.

I have a few of the jobs on my list done

Headlights restored using meguiars restoration kit
Before:
http://i1276.photobucket.com/albums/y471/lukedorney/Mobile%20Uploads/FB_IMG_1476219255965_zpssvdefdkw.jpg (http://s1276.photobucket.com/user/lukedorney/media/Mobile%20Uploads/FB_IMG_1476219255965_zpssvdefdkw.jpg.html)

http://i1276.photobucket.com/albums/y471/lukedorney/Mobile%20Uploads/FB_IMG_1476219252375_zpsma2dc5w8.jpg (http://s1276.photobucket.com/user/lukedorney/media/Mobile%20Uploads/FB_IMG_1476219252375_zpsma2dc5w8.jpg.html)

After:
http://i1276.photobucket.com/albums/y471/lukedorney/Mobile%20Uploads/FB_IMG_1476219248332_zpsdlm607to.jpg (http://s1276.photobucket.com/user/lukedorney/media/Mobile%20Uploads/FB_IMG_1476219248332_zpsdlm607to.jpg.html)
only took the one picture

fitted front fogs:
http://i1276.photobucket.com/albums/y471/lukedorney/Mobile%20Uploads/FB_IMG_1476219181434_zpsdubydvpd.jpg (http://s1276.photobucket.com/user/lukedorney/media/Mobile%20Uploads/FB_IMG_1476219181434_zpsdubydvpd.jpg.html)

http://i1276.photobucket.com/albums/y471/lukedorney/Mobile%20Uploads/FB_IMG_1476219176826_zpsq8tvfuj9.jpg (http://s1276.photobucket.com/user/lukedorney/media/Mobile%20Uploads/FB_IMG_1476219176826_zpsq8tvfuj9.jpg.html)

http://i1276.photobucket.com/albums/y471/lukedorney/Mobile%20Uploads/FB_IMG_1476219170876_zps0k9zsxiu.jpg (http://s1276.photobucket.com/user/lukedorney/media/Mobile%20Uploads/FB_IMG_1476219170876_zps0k9zsxiu.jpg.html)

http://i1276.photobucket.com/albums/y471/lukedorney/Mobile%20Uploads/FB_IMG_1476219165240_zpsmo9bahw3.jpg (http://s1276.photobucket.com/user/lukedorney/media/Mobile%20Uploads/FB_IMG_1476219165240_zpsmo9bahw3.jpg.html)

http://i1276.photobucket.com/albums/y471/lukedorney/Mobile%20Uploads/FB_IMG_1476219160900_zpslaqo1cjq.jpg (http://s1276.photobucket.com/user/lukedorney/media/Mobile%20Uploads/FB_IMG_1476219160900_zpslaqo1cjq.jpg.html)

http://i1276.photobucket.com/albums/y471/lukedorney/Mobile%20Uploads/FB_IMG_1476219154982_zpsumkggb3s.jpg (http://s1276.photobucket.com/user/lukedorney/media/Mobile%20Uploads/FB_IMG_1476219154982_zpsumkggb3s.jpg.html)

Fitted the boot spoiler would have liked to get the extreme hatch spoiler originally but once I saw this one fitted up I much prefer it
http://i1276.photobucket.com/albums/y471/lukedorney/Mobile%20Uploads/FB_IMG_1476219340959_zpswvqimndu.jpg (http://s1276.photobucket.com/user/lukedorney/media/Mobile%20Uploads/FB_IMG_1476219340959_zpswvqimndu.jpg.html)

also done a few interior jobs, I changed the steering wheel as my old one was abit passed it
http://i1276.photobucket.com/albums/y471/lukedorney/Mobile%20Uploads/FB_IMG_1476219935703_zpskziqww3r.jpg (http://s1276.photobucket.com/user/lukedorney/media/Mobile%20Uploads/FB_IMG_1476219935703_zpskziqww3r.jpg.html)

http://i1276.photobucket.com/albums/y471/lukedorney/Mobile%20Uploads/FB_IMG_1476219940102_zps00gu8iyg.jpg (http://s1276.photobucket.com/user/lukedorney/media/Mobile%20Uploads/FB_IMG_1476219940102_zps00gu8iyg.jpg.html)

and I carbon wrapped the centre console
http://i1276.photobucket.com/albums/y471/lukedorney/Mobile%20Uploads/FB_IMG_1476219494555_zpspp6bhudn.jpg (http://s1276.photobucket.com/user/lukedorney/media/Mobile%20Uploads/FB_IMG_1476219494555_zpspp6bhudn.jpg.html)

Pretty sure thats all for now. it will probably be the new year before I do any more big jobs on it

[peterzs]

Looks a lot better already.

Good Luck with the rest of it.

I got an advisory on both front jacking points showing rust. Seems to be a problem area that needs sorting.

:):):)

[Dan1971]

Great work on the lights and that steering wheel was in terrible order. Good change.

[LukeZS96]

yeah it was, the steering wheel was from a 2002 mk1 and there is a big difference in quality IMO. I was very pleased with the headlights aswell, they were letting the side down big time

[LukeZS96]

Small update here. I was up with the body shop Tuesday evening and they have the front jacking points and the rear of the front arches brushed back and treated. Should hopefully have the car back in Saturday night. Then hopefully start the front brake conversion!
http://i1276.photobucket.com/albums/y471/lukedorney/Mobile%20Uploads/2017-02/3906C2AC-B2C7-4925-8473-7841A2CCF941_zpseffdprxh.jpg (http://s1276.photobucket.com/user/lukedorney/media/Mobile%20Uploads/2017-02/3906C2AC-B2C7-4925-8473-7841A2CCF941_zpseffdprxh.jpg.html)

http://i1276.photobucket.com/albums/y471/lukedorney/Mobile%20Uploads/2017-02/88970CE2-9D1A-4066-B6C4-47A86B693099_zpsiepaji5h.jpg (http://s1276.photobucket.com/user/lukedorney/media/Mobile%20Uploads/2017-02/88970CE2-9D1A-4066-B6C4-47A86B693099_zpsiepaji5h.jpg.html)

[peterzs]

Just sorted the rust in the same places on my one, seems they all go there.

[talkingcars]

My mk1 was ok there, what's left of the shell still is but my mk2 is really flaky there.

[LukeZS96]

Yeah this was the same. It wasn't too flaky but there was alot on the surface. All it needed was to be wire brushed back, treated with Hammerite rust remover gel and then 2 coats of hammerite underbody sealant. I was up there again tonight after work and They have the body kit off and sent to the spraybooth, the inner sills have been painted in stonechip, the whole chassis is now covered in waxoyl and the 2 rear anti-roll bar mounts have been replaced. Didn't get any pictures because my phone died but hopefully I should get some when I get the car back on the weekend.

[LukeZS96]

So an update on this thread. First of all my 11s have gone off to be refurnished so she is on hairpins at the minute. There has also been some changes to my plans and i haven't done a whole lot of work to the car since it's become my daily driver again. I am putting the 1.8 out of my Mk1 scrapper into it and I'm going to tune that up with a custom exhaust, remap, 135 cams, a 52mm tb, maybe an alloy inlet manifold and if the headgasket ever gives up in future the head will be ported and polished when it comes off. While the engine is being swapped out I will be doing a few jobs such as the clutch, timing belt and the rear crankshaft oil seal. I was going to replace the headgasket but I thought to myself if it's not gone there is no point in doing it. I am just waiting on the clutch to arrive and then I can take some time off work to do the engine swap. The motivation had dropped off abit due to a few personal issues with work and stuff and money issues aswell but I'm back on my feet now and things are starting to pick up. The work will start on it more hands on again and it will live up to the title of this thread when it's done

[Dan1971]

Good plans - quiet on here so look forward to the updates.

I'd maybe re-think about the headgasket if it hasn't been done. I've never had a 4cyl, but they seem to be vulnerable even if maintained and people go for a better gasket - MLS I think. Your call. Be a shame though to potentially damage the engine in the long term, for the sake of a gasket while the engine is actually out anyway.

Glad your personal bits are sorted too.

[LukeZS96]

I was going to do the head gasket while the engine was out initially but I was told to hold out until I had the engine run for about 5/6K as the car has been sitting up for a while so I can get fresh oil around the engine for a bit to clean up any carbon build up or sludge before I go ripping the engine. I know the headgasket is sound in it so its safe to drive for a while

[talkingcars]

IMHO if it ain't broke don't fix it.

[LukeZS96]

Right so the 1.8 engine is in and its all wired up. Engine is turning over but it won't fire. It's getting fuel but doesn't seem to be getting a spark. Has new spark plugs and the lwads and coil packs came off the old 1.4 engine and they were known to be good. Timing is 100%, compression across all 4 cylinders is perfect, good oil pressure, all relays/fuses are okay, replaced crank position sensor, cam position sensor, throttle position sensor and Idle air control valve and still no joy. Any ideas on what to go for next?

[Drew]

Start with the basics. Are you getting a spark from any/all of the plugs? Do you have fuel getting into the cylinders?


Drew

[Drew]

Lol perhaps I should have read the post!
Do you have 12v at the coil with the ignition on?
Do you still have 12v when it's turning over?


Drew

[LukeZS96]

Got it sorted, seems to be an issue with the ECU, it was a 1.8 ECU and when it was mapped to be unlocked it was mapped for a lucas system and not a pektron system, I put in the 1.4 ECU and she started and ran but I know it wont run 100% with that so I have to either sort myself out with a full Mk2 ECU and BCU set or get my original ECU mapped for a 1.8

[LukeZS96]

God didn't realise how long it has been since this has been updated. So for those who don't know a week before Christmas (as is always the way) my 1.8 engine decided it no longer liked oil flowing through the oil rail and starved the gearbox side of the engine of oil when I was halfway down the motorway to work doing 120 km/h so needless to say it was knocking very very badly after and then locked up completely just as I was pulling up to the house after work. So while I was pondering what to do with it I picked up a nice little Rover Streetwise in PBT with 80K miles on the clock for €900. With the ZS I was always going to be putting it back on the road as it means way too much to me to just scrap it or break it for parts so I decided I would put a 1.8T engine into it which was my original plan with it all along. So after spending the whole month of January searching I picked up a Rover 75 Mk2 connesuer SE for the engine. Less than 60K on it, engine ticking over like a mouses heart I thought I had a minter on my hands and after driving it home over two and a half hours from Banbridge Co. Down without it missing a beat I was pretty pleased with myself but then after a week or two of driving it the headgasket went but I went ahead with the swap anyway, obviously thanks to the snow we had in March it knocked things back abit and after I put the 1.8t into the ZS I stripped it down to discover why it had gone. Someone uses the MLS gasket when the liners were out of tolerance and there was 2 thermostats in it, the PRT stat should rule out the need for the one in the housing under the manifold but someone instead of fitting a blanking plate fitted a proper thermostat causing the engine to run hotter than normal. Anyway the head needed skimming but was abit too close to the limit and I managed to get a head from Sam Tomkins when I was at POL. Needed to get new valves and tappets which arrived only yesterday so now next week I hope to get it all built up and hoping to be turning it over for the first time by Saturday! Needs a few other bits aswell, needs to be mapped, I'm waiting for polybushes for the front lower control arms and also waiting for my 282mm discs, pads, calipers and carriers for the front. Hoping to have it NCT'd and back on the road the end of May then I can start working on my Merc again and my ZR that I got for free

[Dan1971]

Couple of projects on the go then .... good luck with it. Hats off to you guys giving stuff like this a go.

[peterzs]

Yep, good luck, you deserve it.

[p_b82]

That's not been ideal situation, but fair play for sticking with it all.

Hope this is the last of the issues with the 1.8T you have!

[LukeZS96]

With the N-series head bolts and oil rail, coupled with the PRT stat and a good cooling system I should be well protected against future HGF, while it was all apart I rebuilt the turbo during my spare time in work so I know it will all be spot on once it's back together. To be honest rather be doing the HG now while it's off the road rather than have it all done and back together and it blowing after a hundred miles or so. Also gave me a chance to check condition of pistons and liners which all look perfect. I got the new valves into the head and fitted new oil seals, springs, caps and collets and have the new tappets in, beginning to see light at the end of the tunnel now

[LukeZS96]

Time for another update on this I suppose. The engine is back together with a the newly built head and gasket, fresh timing belt and waterpump fitted and all the ancillaries fitted onto it. The intercooler and pipework is all back together along with most of the cooling system and all the fuel lines. Have the hubs fitted back with fresh wheel bearings and lower ball joints. I also have hardrace front lower control arms from a Honda Civic MB5 fitted and new upper control arms also so the front suspension is practically brand new. The engine has cranked over and a compression test gave me readings between 130 and 132 psi across the 4 cylinders and the oil pressure was reading about 3 bar which at cold is practically bang on so I can be confident about this engine. Just need to sort out brakes which I'm going with 282 vented on the front, get my exhaust sorted and then get it remapped and she will be good to go. Sorry I have no photos but my laptop is broken atm and I still have to find a decent hosting website to share photos on here. If anyone wants to have a look at them though and you are on Instagram feel free to give me an auld follow @ luke_zs96 as that's the platform I tend to update the most

[talkingcars]

Sounds like you've been busy.

[LukeZS96]

Latest update on the 1.8T. She is running 100% now just to get the exhaust fabricated, the ECU remapped and a set of tyres for the 11s so hopefully she will be on the road very very soon and it will be at POL 2019. Here's a quick you tube video I've thrown together as a walkaround and the first start of the engine
https://youtu.be/U6nDjO9RxS0

[peterzs]

WELL DONE, hope it all goes well.

[Dan1971]

Good effort - glad it started eventually !!!

Engine bay looks good - even though purple's far from my fav colour ... ;)

[p_b82]

Congrats to you there :)