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Project Ayia Rate Topic: -----

#1 User is offline   slayllian 

  • Group: Members
  • Posts: 68
  • Joined: 20-June 11

Posted 31 August 2011 - 07:53 PM

I was in the market for a second hand car costing no more than 1k, my finance deal was set to end and I didn't fancy chucking more money down the drain on a new car.

I was looking for a fiesta (my sister-in-law had a reliable little runner) but then realised for the same money I could pick up a Puma of the same age, seemed a bit of a no brainer! I set about hunting for cars in my area, but the closest I could find in my budget was in Ipswich. I left it a couple of days and decided to go on the friday after work, with the intention of placing a deposit if all was well.

I checked the net that morning and the car had gone. I hadn't looked the car over yet, but I had somehow become attached (I know this is a bad thing). I contacted the dealer, who told me that someone liked the car and was coming back for a second look. I shot the 40 odd miles to Ipswich, crazy I know! When I arrived the car was gone..... wasted trip!

But as it turned out it was only on a test drive. Cut a long story short, person on test drive didnt buy car, I bought car, person coming back for second look in afternoon missed out! popular little cars! :grin: And that was that, I had fallen for Pumas, she has a peachy little engine, the body was a little rough around the edges (somebody had gone crazy on the rear arches, with something that looked like Hammerite).

I have had her for just under a month and I think this project is turning into a bit of an obsession. We have affectionatley nicknamed her Ayia. I want to get the suspension, bodywork and rust sorted as my primary goals, I will eventually modify her, but only subtly and in favour of enhancing the handling and performance.

The first picture of the car, complete with caved in front wing and horrific arch repairs:
Posted Image
Ayia (29) by Slayllian2, on Flickr




I will update this list as I go (check back on this list, as updated often)

Since February, the previous owner had replaced:

    exhaust, middle and rear sections,
    Both inner CV boots,
    Both anti roll bar drop links,
    3 tyres (need to get another matching on the rear)


The car also received a new remote key and had a full service carried out. It had been kept running but that was about it, everything had been done on the cheap. One omission I noticed was no cambelt change, so I had my ford dealer (Busseys) replace it. I got the water pump changed at same time, all in for £360.

I want to get all major components back to OE quality or better if I can. A lot of the suspension bushes and mounts were shot, so they need sorting.


Things done:

    Cambelt & water pump change
    Fix air filter box, and reattach intake pipe
    Replace missing front rubber skirt
    Replace leaking rocker cover gasket
    Install new speakers all round
    Replace stereo, with correct silver CD6000
    replace broken door handle trim</STRIKE>
    Fit OEM floor mats
    Remove exterior panels, check for rust/clean up
    Fit stereo remote controls
    Replace rear view mirror
    Clean headlights internally
    Replace broken gear shroud trim
    Fix gearbox oil leak
    Fix water leak (into drivers footwell)
    Strip, clean interior, treat any internal rust
    Replace gearbox oil
    Renew gearbox breather
    Clean up and underseal chassis
    Replace drivers front seatbelt
    Recondition alloy wheels (Black)
    Replace number plate fasteners
    Fit Focus 2011 fan washer jets
    Fit ford gel overlays on badges
    Repaint wing mirrors and bumper inserts gloss black
    Replace rear axle spacers
    Clean and lubricate rear brakes
    Weld sills
    Fit new top mounts & bearings
    Clean MAF sensor
    Rust treat beams and sills internally (Bilt-Hamber Hydrate 50)
    Replace OEM rear bushes with PowerFlex Poly
    Replace rear ABS probes
    Fit stainless back box
    Sort rusty arches & sills
    Respray doors, wings and bonnet
    Fit clear side repeaters
    Oil & filter change
    MOT
    Replace fuel filter
    Renew spark plugs
    Renew rear top mounts
    Replace n/s taillight
    Replace pollen filter
    Remove spare wheel, replace with tyre repair
    Renew both rear ABS rings
    Fix ABS gremlins
    Fit braided brake hoses and renew brake/clutch oil
    Replace wheels (Fox FX004's Black)
    Replace tyres (Toyo TR1's)



Things to do (in order I plan to do them):

    Fit front mud flaps
    Install Fiesta ghia external temp sensor
    Fit Aerotwin wipers
    Replace handbrake cable
    Replace aux belt
    Clay & detail car
    Fit Pipercross Viper induction kit
    Fit uprated headlight bulbs
    Renew HT leads
    Fit uprated Brembo discs and pads
    Sort jammed drivers door lock
    Fit Spax struts and springs
    Fit front & rear strut braces

After a good clean and some touching up on the rear arches:
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AYIA by slayllian, on Flickr
http://www.flickr.co...N05/5925893574/

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264951_10150254095274655_769604654_7259339_7922390_n by slayllian, on Flickr


When I got the car back, I gave her a quick wash only to discover the next morning that the drivers footwell was sodden (I bought the car in lovley sunshine, when we were having that dry spell). I set to work trying to find the leak and managed with the help of my wife and a hose pipe to trace it back to the bottom of the windscreen. I had to remove wipers and cowling to get at it properly. to fix I simply ran a bead of clear bathroom sealant along to bottom of the screen making sure not to block the drain holes. This seem to date, to have cured the leak (touch wood).

Now that the car is water tight, I removed a lot of the the rotton underlay and the rest has finally dried out. I can now go and get some fancy velour mats which I have ordered form the main dealer today. With the carpet back I also cleaned up the footwell the best I could. When refitting the carpet I also fixed the clips which hold the edge of the carpet to the sill, this rather annoyingly kept pulling up evertime i got in!

Next thing after fixing the leak I decided to remove the wheels and arch liners and give both a thorough clean, there was at least 2 inches of dirt sitting in the bottom of both front wings and so much on one side that the whole bottom of the wing has rotted through so the wing is only fixed at the top. I then painted all the exposed areas of the suspension and brakes I could get at.


Front arch after cleaning, painting:
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269632_10150251245154655_769604654_7231021_55171_n by slayllian, on Flickr

Rear Arch (liner replaced):
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261315_10150251244564655_769604654_7231013_1154565_n by slayllian, on Flickr

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267512_10150254095169655_769604654_7259338_7096226_n by slayllian, on Flickr

Here is a picture of the rear after I gave it a quick polish the other week. When I picked up the car it had a terrible bodge job on the rear arches, so I sanded them down and used halfords primer and moondust silver and laquer, this gave a much smoother less noticable finish, but there is a slight difference in tones between the panels which really annoys me. But this is only a temp soloution as I already have a quote for £550 to fix both arches and replace the front N/S wing.

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264292_10150251244719655_769604654_7231015_7441454_n by slayllian, on Flickr

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262249_10150254095054655_769604654_7259337_2020978_n by slayllian, on Flickr

Here is what I was up to last weekend, I had the spare wheel off and both rear wheels. I then removed the rear bumper using one of scubasteves great guides. There was a fair bit of rust on the underframe at the rear, the rest of the car was ok tho as it has been undersealed in the past.

But back to the rear, I cleaned it up with a wire brush and removed the fuel filler pipe (as there was a lot of rust under here). I then used kurust and treated the whole underneath of the rear. I then used the trusty Hammerite and gave the whole back end including the leading edges of the bumper beam a good coat. I also treated the rear wheel arches in the same way, and made sure to get into all the little rust traps! When fixing everything back together, I gave the spare wheel and holder a coat of hammerite black, and re pressurised the spare wheel to the correct level. And also while I was underneath I cleaned up the rear beam and gave a coat of hammerite black.

This weekend I plan on going under again and tyding up a bit and polishing all pipes and fixings.

when I get the funds together I will also invest in a waxoyl sprayer as I intend to fill all the box sections and sills full of the stuff before winter.

After a quick wash down, there is a fair bit of rust on the N/S box section
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265131_10150254095449655_769604654_7259341_8092909_n by slayllian, on Flickr

Arches, Bumper beam treated
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263568_10150251244384655_769604654_7231010_1638030_n by slayllian, on Flickr

Before replacing fixings and spare wheel:
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270180_10150251244459655_769604654_7231012_7608871_n by slayllian, on Flickr

Finished off
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262356_10150254094909655_769604654_7259335_2072169_n by slayllian, on Flickr

Spare wheel
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270415_10150254095529655_769604654_7259342_4537725_n by slayllian, on Flickr

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Ayia (92) by slayllian, on Flickr

Gave the engine a good gunking (which it needed from rocker cover oil leak) then started detailing the engine bay, noticed the air filter housing lid was bust so i put good old super glue in the holes and put the screws back in, this seems to have generated new threads, result!

I then found the intake into the filter box, which stangely comes out of the near side wing? was broken where it attaches ti the box and kept falling off, I fixed this by slipping a self tapper into the attachment. There was also a cable hanging off near the gearbox which I reattached.

Quick clean up:
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270026_10150251245499655_769604654_7231028_5234401_n by slayllian, on Flickr

I bit the bullet and bought a new front valance from my local ford dealer, after much searching ebay with no sucess. This was a really easy job to fit, but I decided to use bolts and locknuts instead of the rivets provided, just incase I want to remove it in the future, plus I had no rivet gun lol!

Before:
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264815_10150251245324655_769604654_7231026_1968866_n by slayllian, on Flickr

After:
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270476_10150251245424655_769604654_7231027_1709358_n by slayllian, on Flickr

I also sprayed the bottom edges of the bumper as it has previously been scuffed ito a pavement or something similar. Im really pleased with the results, I think the valance tidies up and finishes the front of the car.

I swapped the the stereo which came with the car, which was the wrong colour and really bugged me. I managed to find the correct cd6000 in silver on ebay for £45. I though about getting the mp3 version from the mondeo but these seem like gold dust!

before
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263561_10150254094994655_769604654_7259336_344053_n by slayllian, on Flickr

after
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268569_10150254095344655_769604654_7259340_566107_n by slayllian, on Flickr

This post has been edited by slayllian: 27 April 2012 - 09:25 AM

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#2 User is offline   slayllian 

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Posted 31 August 2011 - 08:09 PM

Gave the puma a good interior clean over the weekend. I ran out of autoglym interior shampoo so rummaged around and found some left over rug doctor for those carpet cleaning machine you hire, and I gotta say the results were incredible, this stuff is ten imes better than autoglym, i just used it with warm water and a micro fiber cloth.

I removed the interior panels and seats to give the car as good a clean as I could, (and found a pound coin in the process) get in!

I also fitted my ford oem mats which I managed to wrangle for £43.50 from the main dealer, word of caution however, dont twist the locking clips to hard into the carpet as they sheer off, as did one of mine. So I ordered a couple more spares from ebay.


Front seat removed:
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Ayia (109) by slayllian, on Flickr

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Ayia (108) by slayllian, on Flickr

Rather scarily this much dirt was hiding in the drivers seat alone:
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Ayia (107) by slayllian, on Flickr

Removed the rear bench and gave underneath a good scrub:
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Ayia (88) by slayllian, on Flickr

Found this behind drivers side rear panel:
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Ayia (86) by slayllian, on Flickr

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Ayia (87) by slayllian, on Flick

So as usual kurust and hammerite, my bodge soloution for everything!
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Ayia (89) by slayllian, on Flickr

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Ayia (99) by slayllian, on Flickr

Also found some rust on the bottom edge of the drivers door, which I treated in same way:
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Ayia (97) by slayllian, on Flickr

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Ayia (98) by slayllian, on Flickr

The 3 n/s carpet plugs were missing, which I promptly replaced:
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Ayia (100) by slayllian, on Flickr

Also replaced my grubby window switch trim:
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Ayia (2) by slayllian, on Flickr

With this one from ebay:
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Ayia (3) by slayllian, on Flickr

All finished, rather proud for a days work, and found a quid! result! lol
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Ayia (112) by slayllian, on Flickr

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Ayia (6) by slayllian, on Flickr

Will put more updates soon, these cars should come with a health warning, they take over your life! lol

I also noticed an annoying rattle on way home from work on friday, which took ages to locate, it turned out to be the rear drivers side brake pipe rubbing on the sill. I fixed this by applying foam padding with insulation tape around the pipe.

While I was there I started to paint the underframe with the black hammerite I had left over from painting the suspension. I need to wait until I get some axle stand to get all the way under.

The sills seem in pretty good shape at the moment so I hoping to keep them that way lol.
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Ayia (90) by slayllian, on Flickr

I have also fitted these 6x9s I had laying around into the rear housings, they were incrediblly easy to fit, only requiring a lottle cutting of the box and they really make a difference sound wise!

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Ayia (93) by slayllian, on Flickr

ast thing today I fitted my sat nav, but I didnt want the wire hanging around the front of the center consol, so I routed it up the back. The only trouble with this was that the ash tray wont shut and jams the cable. So I modified the rear of the ash tray and as I dont smoke use it as the storage tray for the charger. when I want to use the sat nav I only have to open the ashtray and plug in the charger, then its out of sight the rest of the tim

Cut out in rear of ash tray (used snips and file to make cutouts):
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Ayia (94) by slayllian, on Flickr

In use:
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Ayia (95) by slayllian, on Flickr

Routed the cable along bottom edge of dashboard and up behind weather strip (wire is just tucked in vent when sat nav is not in use for neatness):
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Ayia (96) by slayllian, on Flickr

Only thing left to do is download a puma logo for my satnav start up screen!

Just ordered my focus/mondeo stereo remote from ebay, so will be fitting that this weekend.

on another note, I need to do somthing temporary with this arch, until I get the money together to get it and the rear arches done at the bodyshop. I cant weld (least not very well)so I was thinking of maybe reconstructing the bottom with some fibreglass or somthing? It looks like somthing has been hit and caved the inside of the arch in at some point, I pulled it out a bit but pulled the wing off in the process, as the whole bottom of the wing had rotted through!

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Ayia (66) by slayllian, on Flickr

l will be giving the engine its first real detailing tonight, I had planned to wash & wax the car but the weather has other plans! will post some pictures up!

Water has decided it wants to make its way into my now clean footwells once again and all over my lovley new mats! Posted Image so its back to the drawing board, think tomorrow im going to remove rubber seal dig out all the previous bodge attempts and try to seal it up good and proper! I will post some pics for deffinate this weekend!


had another go at fixing the water leak friday night, hopefully for the last time, if not I will get the window replaced:

Removed all the surrounding parafinalia, gave everything a good clean up at the same time:
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001 by slayllian, on Flickr

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003 by slayllian, on Flickr

Put silicone behind seal also:
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002 by slayllian, on Flickr

Gave engine a quick detail and clean, oh and I removed the carpet lining and resonator box (for cleaning):
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004 by slayllian, on Flickr

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puma by slayllian, on Flickr

This post has been edited by slayllian: 31 August 2011 - 08:10 PM

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#3 User is offline   happy-kat 

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Posted 31 August 2011 - 08:17 PM

Wow you have been busy. :)
Some thoughts while I don't forget them.
Gearbox breather only goes one way, it leaks if in the wrong way round.
Did you use the cam belt kit with the job? Only the tensioner must be changed on the 1.7 and the kit includes it and a new stretch bolt and stuff.
You can buy the metal bits to use to cut out and replace the rust on the rear arches. There are two options (plus make them directly), either a pugeot panel (there is a thread on this) or you can buy I think it's from Germany a metal curve for the Puma.
The Wiki has a water water every where article on possible leak entry points, plus other articles like where on the inside/interior you might want to go and look to treat your arch rust.
The F1 alloys were an option, but there was a very small period of production where they got used anyway from memory.
Your VIN number can be decoded to find out the month/year that your Puma was actually made.
The VCT babge is no certainty of first 1500, my March 1999 Puma had one, plus you can buy that badge.
Look forward to your updates.
searching is fruitful | I'm a sponge not a mechanic | please do try that if stuck with a Puma problem whilst waiting for a reply | For the Puma fan this read 'The Inside Story Book' is very nice to own sometimes still seen for sale

#4 User is offline   happy-kat 

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Posted 31 August 2011 - 08:25 PM

You found the interior rear arch issue :(
This is the water water everywhere article
http://www.pumapeopl...ater_Everywhere
searching is fruitful | I'm a sponge not a mechanic | please do try that if stuck with a Puma problem whilst waiting for a reply | For the Puma fan this read 'The Inside Story Book' is very nice to own sometimes still seen for sale

#5 User is offline   slayllian 

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Posted 01 September 2011 - 08:22 AM

I will see If I can decode the chassis code, be interesting to find out. Yeah I found my breather was the wrong way round, spent plenty of head scratching to find it, lol! thanks for all the info! Ford did the cambelt and water pump using OEM kit.
I should explain that I have this thread on another forum, but have just started up on here, so a lot of catching up to do. haven't managed to do all the work in one goPosted Image lol, had the car a couple of months now, will keep you guys updated.
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#6 User is offline   slayllian 

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Posted 01 September 2011 - 08:45 AM

View Posthappy-kat, on 31 August 2011 - 08:25 PM, said:

You found the interior rear arch issue :(
This is the water water everywhere article
http://www.pumapeopl...ater_Everywhere



Thanks for that link happy-kat, god wish I had found that link sooner, that was exactly where my leak was coming through the scuttle plate, dohh!!



I gave the arches another quick respray as the rust had started to come back through already:

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048 by slayllian, on Flickr

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049 by slayllian, on Flickr

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050 by slayllian, on Flickr

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060 by slayllian, on Flickr

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051 by slayllian, on Flickr

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062 by slayllian, on Flickr

Hope this will hold it off a bit until they are properly repaired :-)

I removed the front panels to check and repair any rust, I knew my front N/S arch was badly corroded but wanted to see what it was like underneath:

first things, I planned to start this wedensday after work, but confronted with this:
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016 by slayllian, on Flickr

luckily weather not so bad next day, started removing panels:
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025 by slayllian, on Flickr

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026 by slayllian, on Flickr

Here is the state of the front wing, ill be replacing it very soon, but just painted over rust for time being:
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028 by slayllian, on Flickr


Luckily the sill underneath is in good condition, but the wing mounting plate is a little corroded.
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027 by slayllian, on Flickr

Gave everything a quick clean up:
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030 by slayllian, on Flickr

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032 by slayllian, on Flickr

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033 by slayllian, on Flickr

Sorted the front sill out:
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036 by slayllian, on Flickr

Touched up any rust I found:
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038 by slayllian, on Flickr

Overall didnt really find much rust she has aged gacefuly lol!
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039 by slayllian, on Flickr

Puma has this concoction for an air intake, ford must have put it there for a reason, so i popped it back in:
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040 by slayllian, on Flickr

Hiding in her rather messy den, all finished:
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042 by slayllian, on Flickr

the bumper wasnt hanging right after I put it back together, so I had a fiddle and got it like this, quite happy now:
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055 by slayllian, on Flickr

Added the remote stereo controls, managed to pick one up on ebay really cheap and just used some speaker cable I had laying around to connect it up.

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076 by slayllian, on Flickr

I managed to position it close to the wheel so my fingers can reach it while im still holding the wheel:
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077 by slayllian, on Flickr

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079 by slayllian, on Flickr

This is one mod that is really worth doing, as it makes life so much easier and you dont have to take your eyes off the road to fiddle with the stereo 8-)

This thing had been floating around the engine, found where it goes, just clips in, think its the cover for the HCV:
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Ayia 2 (5) by slayllian, on Flickr

replaced my broken mirror, but found it would not stick unless the residue from the last sticky pad was completly removed from the window. I opted to go for a genuine brand new mirror (not cheap @ £50!):

The old mirrors metal casting snapped when I tried to adjust the mirror because it was stiff:
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Ayia 2 (2) by slayllian, on Flickr

Removing old sticky pad, used some alcahol cleaning soloution and a blunt plastic scraper
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Ayia 2 (3) by slayllian, on Flickr

New mirror fitted, just pressed on firmly, took a day or so to set fully:
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Ayia 2 (4) by slayllian, on Flickr
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#7 User is offline   slayllian 

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Posted 01 September 2011 - 09:11 AM

Driving home in the dark I learned, was rather scary in a ford puma! So I decided to try and improve the situation by cleaning the lights. Only problem was I needed the car for the next day so I had to put the lights back on, thus the condensation! but that has cleared itself after a couple of days and driving everywhere with the lights on! Posted Image

The lights were really filthy, which doesn't really show that well in photo:
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Ayia 2 (6) by slayllian, on Flickr

Washed out wih de-ionised water (to stop water marking):
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Ayia 2 (8) by slayllian, on Flickr

Lights are much brighter (condensation has now cleared):
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Ayia 2 (9) by slayllian, on Flickr

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Ayia 2 (12) by slayllian, on Flickr

On another note, I refitted the bonnet liner and resonator box. I have made a temporary repair on the liner until I get a new one.

This was before, I just dabbed the damaged area with some black model makers weathering powder (from my airfix days) to blend it in as in pic above :
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Ayia 2 (10) by slayllian, on Flickr

Decided to sort rust in footwell from the water leak (bit mouldy down there):

Pulled carpet back to gain access:
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Ayia 2 (14) by slayllian, on Flickr

Chipped away loose paint/rust, then used kurust to treat area:
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Ayia 2 (13) by slayllian, on Flickr

Hammerited over top of area, followed by sealant and then another coat of hammerite:
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Ayia 2 (16) by slayllian, on Flickr

A few pics of the project as it stands (doesn't look much different yet I know)...

Interior:
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Ayia 2 (17) by slayllian, on Flickr

Engine (really pleased how this has come up):
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Ayia 2 (15) by slayllian, on Flickr

Exterior:
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Ayia 2 by slayllian, on Flickr

My wheels need refurbing and I came across a thread about spraying standard puma alloys black, got me thinking.

I generated these in Photoshop.

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5934002823_d4be8cc4cc_b1 by slayllian, on Flickr

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5934563052_fc20e8c4fe_b by slayllian, on Flickr

Finished off painting the front arches, all that I have to do now is get her up on the jacks and paint her undersides.

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Aiya by slayllian, on Flickr

Another problem my car had was the seal had gone on the rear n/s tail light, causing dirt ingress:
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Aiya (7) by slayllian, on Flickr

cleaned the same as before and silicone sealed after it had fully dried out (its not come up to great so I will need to replace the unit when I can afford it):
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Aiya (9) by slayllian, on Flickr

This post has been edited by slayllian: 01 September 2011 - 09:12 AM

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#8 User is offline   slayllian 

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Posted 01 September 2011 - 09:17 AM

I replaced the broken gear leaver surround, picked one up on ebay for £15

Original broken trim:
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Aiya (11) by slayllian, on Flickr

Spot the difference, gone for a later puma style badge without the VCT:
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Aiya (12) by slayllian, on Flickr

Fitted in car:
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Aiya (13) by slayllian, on Flickr


Finally couple pictures of my car cleaned up:
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Aiya (16) - Copy by slayllian, on Flickr

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Aiya (15) - Copy by slayllian, on Flickr

Got plenty more jobs to do, will update as I go along Posted Image
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#9 User is offline   slayllian 

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Posted 01 September 2011 - 09:24 AM

Quick update, oil leak now fixed:

Basically the breather was the wrong way round,

However unfortunately whilst re-checking the gearbox level I dropped a piece of cable tie into the box never to return, no matter how much I fished it! So I flushed the oil, in the hope of removing the offending object, no luck! I tried again the next day, but it appears to have sort of liquidated into the oil. So I will change the gearbox oil fully in the next month by removing the drive shaft. She is running fine at the moment and the gearbox is as smooth as ever, so fingers crossed!

On anther note, I have had the arches booked in to be done in two stages, October and November, he wants to do a side at a time. Cant wait to see her looking like new!
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#10 User is offline   slayllian 

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Posted 01 September 2011 - 09:39 AM

Some pictures of the gearbox flushing (wondering if anyone can tell me what's going on with the gearbox oil, is it oxygen in the oil making it milky and when it settles, whats that gray stuff is that iron)?

Oil coming out of the filler (previously over full, probably caused the milkyness)
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281 by slayllian, on Flickr

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283 by slayllian, on Flickr

Decanted it into smaller containers:
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282 by slayllian, on Flickr

Settled with this gray stuff in the bottom, think it might be iron from 110000miles wear?
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Italy 2011 040 by slayllian, on Flickr

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Italy 2011 038 by slayllian, on Flickr

Is this some sort of addative?
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My Birthday 043 by slayllian, on Flickr

Trying to flush through with new oil:
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285 by slayllian, on Flickr

I managed to fill from above removing the air pipe and using a funnel:
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284 by slayllian, on Flickr

The gearbox seems to be running ok at the moment, in the above pictures I only drained the oil from the bottom drain plug, so im going to remove a drive shaft in the next couple of weeks and fully drain and replace the oil to get at all the crap sitting in the bottom of the box.

Little bits, the devil is in the detail: Posted Image

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007 by slayllian, on Flickr

replaced with:
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010 by slayllian, on Flickr

its a nightmare to find a mint one of these for the o/s, they are always cracked!

Had another stab at the water ingress and has really reduced it! Think the dash will need to come out to fix it fully though! sealed all the bits up in the scuttle panel with roof sealant, far more durable than bathroom sealant!

Cleared around bulkhead so I could get good access (also used the time to give this area a good clean):
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275 by slayllian, on Flickr

Then used roof sealant to seal all suspect areas (everything) and put all surrounding stuff back:
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276 by slayllian, on Flickr

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278 by slayllian, on Flickr

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277 by slayllian, on Flickr

Gave the engine another quick spruce up:
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279 by slayllian, on Flickr

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280 by slayllian, on Flickr

Also bought this the other day, so I can finally get under the car:

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My Birthday 044 by slayllian, on Flickr

This post has been edited by slayllian: 01 September 2011 - 09:40 AM

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#11 User is offline   slayllian 

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Posted 01 September 2011 - 01:23 PM

Next up I decided to do a temporary repair on my damaged front n/s wing:

Before:
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Ayia (66) by slayllian, on Flickr

As the bottom fixings had rotted away the wing sat proud:
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My Birthday 045 by slayllian, on Flickr

So I fabricated a rather bodge but secure solution to pull it back in:
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My Birthday 046 by slayllian, on Flickr

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My Birthday 049 by slayllian, on Flickr

I chipped off all the loose paint and metal and treated. I also cut away some of the bent in metal with an angle grinder to give a better profile:
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My Birthday 047 by slayllian, on Flickr

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My Birthday 048 by slayllian, on Flickr

I then filled as much as I could:
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My Birthday 051 by slayllian, on Flickr

Then put the car on stands so I could clean and paint some more of the underside while I waited for the filler to cure:
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My Birthday 050 by slayllian, on Flickr

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My Birthday 054 by slayllian, on Flickr

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My Birthday 052 by slayllian, on Flickr

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My Birthday 055 by slayllian, on Flickr

Then I painted the bottom of the wing and tidied up the wheel arch, while the wheels was off:
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My Birthday 056 by slayllian, on Flickr

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My Birthday 057 by slayllian, on Flickr

Finished, a bit tidier, at least its not hanging off:
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My Birthday 059 by slayllian, on Flickr

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My Birthday 060 by slayllian, on Flickr

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My Birthday 061 by slayllian, on Flickr

Mine and the Missus car, trying to persuade her to get a puma Posted Image
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My Birthday 058 by slayllian, on Flickr

Managed to wrangle these for £140 off ebay, bargain: Posted Image

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001 by slayllian, on Flickr

from a fiesta zetec s phase 1, in much better condition than my existing wheels:
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002 by slayllian, on Flickr

They were a straight swap, but had obviously been sitting around for a while as they were all flat:
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003 by slayllian, on Flickr

Think with the lower suspension, they make it look much sportier:
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005 by slayllian, on Flickr

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007e (2) by slayllian, on Flickr

Taken the car off the road for the next week, so I have used the time to strip the interior to sort out any rust and niggling problems.

    These include fixing the water leak through the scuttle plate (now sorted)
    fixing any rust
    waxoyling all prone areas
    replacing both front belts
    cleaning interior carpets & linings
    I also plan to sort the drivers door lock


I will also post a how to guide in the next week or so, on how to remove the interior. I still have a couple of bits to remove (the door cards and seat belts) but I will include these in the guide.

Water coming the scuttle plate, I have now sealed this up:
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050 by slayllian, on Flickr

Dashboard removed:
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049 by slayllian, on Flickr

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081 by slayllian, on Flickr

Carpet removed:
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086 by slayllian, on Flickr

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105 by slayllian, on Flickr

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104 by slayllian, on Flickr

This post has been edited by slayllian: 02 September 2011 - 12:00 PM

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#12 User is offline   happy-kat 

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Posted 01 September 2011 - 03:54 PM

Been well busy :)
Ford do a sticky pad for the mirror that is well strong and better then other bought stuff, in case yours is not the Ford pad (40p or so) it might fall on in due course.
The wiki has an article on cleaning the headlights, but I guess you did that :)
Never seen gearbox oil like that when mine has been drained.
searching is fruitful | I'm a sponge not a mechanic | please do try that if stuck with a Puma problem whilst waiting for a reply | For the Puma fan this read 'The Inside Story Book' is very nice to own sometimes still seen for sale

#13 User is offline   FlashBastd 

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Posted 01 September 2011 - 08:19 PM

The Fiesta wheels are the wrong offset, you may notice that the car won't drive as nicely with them as it does with the original wheels.

Otherwise nice work!
2005 Vauxhall VX220 Turbo
2000 Ford Focus 1.6i Ghia
2006 Renault Clio 2.0i RenaultSport 197 - SOLD
2005 Honda CR-V 2.0i Executive auto
2001 Ford Puma 1.7i Black

#14 User is offline   slayllian 

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Posted 02 September 2011 - 08:35 AM

Thanks guys, didn't realise the wheels had a different offset and yeah the oil has stumped me, just going to replace it.

Quick update: been out doing a little more before I lost the light

removed the door cards, (bit filthy behind there) going to remove the offside door lock and take to the locksmith in the hope that it can be made to work with my key:
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017 by slayllian, on Flickr

Here is some of the rust i'm in the process of fixing up, mostly appears to be around the nearside seat mounts:
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010 by slayllian, on Flickr

Waxoyld the inside of the rear wheel arches (the sills will be getting the same treatment internally):
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021 by slayllian, on Flickr

Gave the inside of the car a good wash, believe it or not this was the 3rd bucket: :shock:
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018 by slayllian, on Flickr

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016 by slayllian, on Flickr

Its now beginning to look much tidier in there: :thumbs:
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022 by slayllian, on Flickr

Got a little heater in there at the moment drying everything out:
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019 by slayllian, on Flickr
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#15 User is offline   slayllian 

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Posted 02 September 2011 - 08:50 AM

View PostFlashBastd, on 01 September 2011 - 08:19 PM, said:

The Fiesta wheels are the wrong offset, you may notice that the car won't drive as nicely with them as it does with the original wheels.

Otherwise nice work!


How can I correct the offset will spacers sort this out? my car is the first batch with the smaller brakes, cheers.



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#16 User is offline   happy-kat 

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Posted 02 September 2011 - 10:29 AM

What offset are the wheels? (it will be printed/stamped on the rim somewhere)

Standard fitment range is ET34-38
searching is fruitful | I'm a sponge not a mechanic | please do try that if stuck with a Puma problem whilst waiting for a reply | For the Puma fan this read 'The Inside Story Book' is very nice to own sometimes still seen for sale

#17 User is offline   slayllian 

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Posted 02 September 2011 - 11:58 AM

View Posthappy-kat, on 02 September 2011 - 10:29 AM, said:

What offset are the wheels? (it will be printed/stamped on the rim somewhere)

Standard fitment range is ET34-38



ET43.5, so I'm going to bite the bullet and buy a brand new set of wheels with fresh rubber. I only really put these on as an interim measure.
the only other option as people have said is wheel spacers and I don't want to destroy the front hub in the process Posted Image



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#18 User is offline   happy-kat 

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Posted 02 September 2011 - 01:30 PM

or the handling really
I expect you may sell them fairly easily
searching is fruitful | I'm a sponge not a mechanic | please do try that if stuck with a Puma problem whilst waiting for a reply | For the Puma fan this read 'The Inside Story Book' is very nice to own sometimes still seen for sale

#19 User is offline   slayllian 

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Posted 04 April 2012 - 01:41 PM

Next I put the car back together after its interior clean/rebuild, I used a carpet cleaner machine with attachment to clean all the interior textiles with, I was shocked with the amount of black/brown water I managed to displace. The results were worth it though as the interior came up like new:

(The fascia was a bit of a pain to get back in due to the wiring harness)

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009 by slayllian1, on Flickr

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012 by slayllian1, on Flickr

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013 by slayllian1, on Flickr

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056 by slayllian1, on Flickr

Replaced the damaged n/s window switch trim:
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054 by slayllian1, on Flickr

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058 by slayllian1, on Flickr
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#20 User is offline   slayllian 

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Posted 04 April 2012 - 01:44 PM

As an interim solution for the incorrect wheels, I reconditioned the original alloys until I can afford some new ones

Current alloys with incorrect offset (sitting to far in):
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036 by slayllian1, on Flickr

Rubbed the original wheels down:
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019 by slayllian1, on Flickr

Some of the original fake split rim nuts had sheered off, so I replaced these with the real equivalent sizes:
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018 by slayllian1, on Flickr

I fitted these with Araldite and re-secured any loose fake nuts with it too!
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020 by slayllian1, on Flickr

Then I primed the wheels:
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027 by slayllian1, on Flickr

Then lots 'O' lovely paint and then lacquer:
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031 by slayllian1, on Flickr

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033 by slayllian1, on Flickr

On the car:
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046 by slayllian1, on Flickr
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