N/S Marlin supplied SS line attached to the inside of the engine bay with 8mm rubber lined P clips and 4.8mm rivets. I've never used a rivet gun before so the first few attempts were a bit vexing but once I got the hang of it, I was well away.

I took the opportunity as I was drilling holes in the chassis to spray waxoil into the box sections to help prevent rust. I also slapped grease in every hole as I was too impatient to hammerite each one and wait before putting the clips in. should have the same effect

Cllr Jason Kitcat in Brighton Town Hall. Photo by Steve George Photography www.stevegeorgephotography.co.uk

Kitc about to pounce on a mouse

IVA test day is tomorrow. I've hired a trailer from a different place to when I took the car for its mini MOT and this one is a much more sensible size. Still 3 foot longer than it needs to be though.

Despite thinking I had nothing left to do, when I went to turn the car around in the road it took a 7 point turn due to the steering rack limiters I installed. In my view this made the car unsafe for the road as you'd struggle to turn through tight bends or make it round a mini roundabout in one move. I figured the examiner would take the same view so set to work modifying them. I was able to chop them down to just 2cm before any issue with fouling of the wheels so I can only assume that my suspension setup modifications have had an impact on clearance. It felt much better when I took it back out to place on the trailer. It was a good job I took two days off to cover any unexpected last minute work.

The battery is on charge over night, the tank is full of fuel and the tow car is jammed full of tools, spares, documentation and can of spare fuel. All I need to do now is wake up on time (5am) and not forget my sandwiches!

loom half out through the hole in passenger footwell. fuse box at the front

枷锁..

Some clumps of oily metal shards have collected in some recessed areas so I carefully scoped them out with a flathead screw driver.

Once I have the engine up and running again I'll use some flushing oil to make sure all this type of thing has been removed

This is the cleaned up and re-installed seal and plate inside the rocker cover that basically allows oily gases to escape from the top of the engine via the breather outlet (top left) with out actual oil splashing out too

New crank shaft position sensor from GSF. This is the "Standard" one for £42. There was a "Premium" one for £65 but with no supporting evidence of why it was better. So I didn't buy it. Time will tell.

I've removed the harmonic damper from the front of the crank hub ready for de-rusting and cleaned up the ali timing case cover as best as I can. I'm going to replace some of the nuts with shiny new ones but without taking it off (including the VANOS) for blasting this is the best I can do.

I tipped the entire engine on it's side for painting as it made reaching some of the parts easier though keeping the spray can at the right angle was more tricky

Repair of the ground off baffle rivet. I drilled through the stump with a 4mm bit and then popped a thread in there with a 5mm tap. You can see where the screw comes out the side of the sump. I guess it is better to have it go all the way through, seal it with some RTV but be able to inspect it to see if it is working loose rather than do a shallow tap and find out it has worked loose when if punches a hole in the engine

Operated by: Kinetic Melbourne

Built in: 02-2009

Manufacturer: Designline

Model: ?

(Chassis): MAN 16.240

Notes: ex-TransDev

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642 seen on Sunbury Line rail replacement shuttle at Sunshine Station.

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Please do not use this image without first asking for permission. Thank you.

Taken with KitCam. kitc.am

view of the front of the engine bay with the SS line going under the steering column

Colonia, Alemania: Foto turistica kitch del Dom tomada desde el Rhin

First of 15 polished up rocker cover fasteners and washers next to an unfinished one. They look better in the flesh as the flash shows up all the scratching around the hex part pretty badly

All cleaned up. the white residue is where I soaked it in washing powder to help break the oil down. it will get a good rinse out before it goes back on the engine

Rocker cover after a few coats of VHT satin black. It's not perfect but much better than it was. I've already managed to chip a little bit as it's not had the full heat curing yet which is a bit annoying

This is how I think the hand brake shoes, springs and original parts will fit together. I suspect the retaining springs should go the other way round to prevent the adjuster fouling, but then the lengths plus photos suggest this is correct.

Just need to sort out the cable now

Operated by: SkyBus Melbourne - powered by Kinetic

Built in: 02-2019

Manufacturer: Volgren

Model: Optimus

(Chassis): MAN 19.320

Notes:

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218 on the value carpark shuttle

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Please do not use this image without first asking for permission. Thank you.

getting some of the rear loom out was a bit of a pig as was removing the rear seat back. I pulled the door card off as I've never been able to open the back door due to the central locking. this didn't help as I still couldn't get at the lock

N/S of block painted up.

Next thing to do is get the sump off and cleaned up then the engine should essentially be ready to drop in the car.

At the same time as getting my wheels done I got them to dip my rocker cover to remove the paint.

I had hoped to have bare metal but the primer coat has remained. All the scum you can still see it easy to pull/scrape off

view from the front of the cleaned up oil filter housing

Final push on the donor car today. Cut out some pesky pieces of carpet and removed the heater to allow the O/S bits of loom out (hence coolant on the floor)

I'm still not convinced I should have wasted time on this but it could help as a reference when I'm struggling to figure out how to get tthe sportster wired up again.

It'll just bee thrown in a large box and filed away until I need it

VANOS solenoid cleaned, polished and re-installed. I didn't bother with a new O-Ring as they cost about £10 each which is a tad steep and there was no evidence of a leak anyway.

I've also cleaned up the cam position sensor and reinstalled (black thing behind) and wirebrushed the engine lifting bracket and re-installed

Popped the sump off today for its cleanup

The engine bottom has a bit more baked on oily stuff than I'd expected. I may take off the oil pump pick up and then that baffle plate to clean up and carefully wipe the scum off the pump.

As that's about all I can do for the moment I may just use a flushing oil once I've run it again for the first time even though every one says not to on old engines

shiranui mai

Rocker cover seals positioned on top of the engine - outer seal and the pair for the spark plug holes.

IVA test day is tomorrow. I've hired a trailer from a different place to when I took the car for its mini MOT and this one is a much more sensible size. Still 3 foot longer than it needs to be though.

Despite thinking I had nothing left to do, when I went to turn the car around in the road it took a 7 point turn due to the steering rack limiters I installed. In my view this made the car unsafe for the road as you'd struggle to turn through tight bends or make it round a mini roundabout in one move. I figured the examiner would take the same view so set to work modifying them. I was able to chop them down to just 2cm before any issue with fouling of the wheels so I can only assume that my suspension setup modifications have had an impact on clearance. It felt much better when I took it back out to place on the trailer. It was a good job I took two days off to cover any unexpected last minute work.

The battery is on charge over night, the tank is full of fuel and the tow car is jammed full of tools, spares, documentation and can of spare fuel. All I need to do now is wake up on time (5am) and not forget my sandwiches!

Taken with Gcam, edit in kitcam