Showing posts with label Seven. Show all posts
Showing posts with label Seven. Show all posts

Friday, September 3, 2010

Rear wheel bearings

I decided to replace the rear wheel bearings on the seven as they were making a bit of noise. To make life easier i knocked up a stand for the rear of the car which means I can stick it on the stand rather than using floor standing axle stands or a trolley jack to support the car. This proved very useful.

Made a small stand to support the car on the lift.

The theory is you remove the hub, and undo the bolts that hold the bearing in place, and use a slide hammer to yank out the half shaft. Not having a slide hammer compounded this, but the first one came out with a few stern blows with two hammers on a back to front hub (providing me with something substantial to hit.)

Removing the rear half shaft

The other took many hours of smacking with hammers, chisels, heat and general swearing before it gave up. I cut a groove into the bearing itself, and then used a cold chisel to break it off, this worked pretty well. The new bearings are now ready to fit, and will get pressed into place by my local garage.

And corroded on, so it was easiest to cut a groove and use a cold chisel

Seven Trip to spain

Not much driving weather this year, however I did manage to get a trip to spain with some friends, they were flying from all over the place, so I drove down through france on my own. The weather was forecast to be wet (Imagine my surprise) so I decided to take it easy over a few days as it can be pretty miserable driving when the water is coming in through the drain holes.

The rain held off long enough for a broodje kaas, and a well deserved pee.

The first day was mainly getting through the Netherlands and Belgium, which is miserable at best, but the rain was just damp rather than biblical, so quite good fun. Northern france got a bit wetter, but started to dry up by the time I got to Dijon. I had a bit of a moment when there was a horrible metalic noise, I thought at first the alternator had come off again, which was surprising as its threadlocked, and lockwired, but alas it was only the number plate which had come off at one side. I just undid it and threw it in the boot where it will stay for the time being.

I went through about half a litre of oil on the way to dijon, so apparently I still have a major oil leak out the sump. Grumble.



The next day was towards the Tarn, the morning was very wet, and very slow, but the roads were nice, and fairly quiet, in the afternoon it turned to random showers, and the scenery changed into some nice twisty mountain roads, i went over numerous cols, and found I far prefer the Yokohama A048 tyres over the Toyos, it just feels more planted.

The sun came out just in time for Mende, so I spent a few hours going up and down Cols and mountain roads, the car is really on form, traffic is minimal and i'm enjoying every second. I stop for some groceries, and go out for another our or so before stopping for the night in a camping.

The next day I followed to Tarn gorge, before heading up the side, and over the Millau bridge. At this point I noticed that the alternator output was lower than it should, and the ignition light was flickering. Having had an alternator fail a year ago I know all about the tell tales signs, but the ammeter was flickering all over the place. I also know that David ashurst has been plagued with ignition light flickering recently and that its caused by an electrical connection in the lucas plug. I pulled over and cleaned it up, and squashed the connector a little to provide a better connection, and the problem was solved.

Traffic was obnoxiously bad so I just followed the coast down to spain and then cutting off a pininsula and coming over an amazing bit of road into calonge.

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The week was spent driving shorted distances over some great stretches of road in the costas, with a different passenger for every trip. The car was in great form for the most part, with a crack in one of the vaccum connectors forming and causing an air leak which was a bit of a pain for the rest of the day until I got back home and resolved it.

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The way back I went pretty much dead straight home, doing around 130kph most of the way up the peage, everything was fine till belgium when I noticed a small water leak when refuelling, there was a pinhole in one of the hoses, so I just cut it off and shuffled it up a little which got me home. I also noticed the fuel consumption was up for the last tank, which turns out was a fuel leak in the tank (again) so I'll add that to the list of jobs to do which is currently:

* Adjust the position of the gear box so it doesn't vibrate against the crossmember on hard left turns.
* Fix the fuel leaks from the tank
* Replace the rear wheel bearings which are getting a little noisy
* Make the speedo work again.

Fuel tank and wheel bearings

I've had nothing but bother with the fuel tank since I had it made to my design by a company in the UK. First they forgot the order, then when it finally arrived it leaked fuel all over the place, and to top it all they over charged my credit card by 100 pounds. I still haven't had a refund for the difference let alone the leak stopped. This all came to a head last week when I went out for a quick drive and could smell petrol. I turned around and went home, when I arrived I could see a steady stream of fuel dripping out the rear of the car, the weld had failed in the swirl pot.

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I decided it was time to get the fuel tank out and fix it properly, before doing so I drained the tank and filled it with water, I could see it driping out of a seam at quite a rate. I took the tank out at this point (which requires dismantling most of the rear of the car.) and decided to pressurize the tank a little so i could find all the other little leaks too. At 5psi the tank burst along the top seam. The welds are terrible, and not very deep, which left a 9" gash along the top.

I didn't want to waste any more summer driving time, so I decided to fix it myself. I borrowed hans' TIG welder and set about learning to weld with it, its not easy, and for some reason I seemed to get electric shocks off the welder very regularly, but I did manage to get to the point where I could run a consistently deep, if not very tidy weld, so moved onto the tank. I welded in a bit of right angled aluminum along the top as the gap was too big for me to weld up again, and welded up the seam at the bottom of the tank all the way along. It stopped leaking streams but it still leaked a drop here and there at 10psi.

I've now sealed the tank with some Tapox tank sealer, so hopefully this should do the trick, over the winter I'll probably get a new one made up as I don't trust this tank any more.

Sunday, August 1, 2010

Trip to Zeeland

It was sunny so I went for a drive in the seven with tunerstudio running to see if I could improve things, I couldn't but the drive was lovely.

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Basically, there is not enough variation in MAP pressure, and the rate of change is very steep off idle with no change at higher rpm. This means that the VE table is pretty flat.





Subsequently, I changed over to TPS based fueling, the result is a much more responsive drive, throttle response is like lightning in comparison, and it feels and sounds like its set up properly. The AFR is much closer to the AFR target. I've only ran autotune for about an hour or so on what was a relatively quiet drive, so the edges are not tuned yet, but for the most part its pretty close. Its certainly very drivable



Whilst I was trying to get Alpha-N working I hit a few idiosyncrasies in the tuning software. There are three fueling options for megasquirt: Speed Density; (MAP Based) Pure Alpha-N; (TPS Based) and Blended.

For now I'm using Pure Alpha-N, however when I set the fueling algorithm to Alpha-N in either tuner studio, or megatune it was still using MAP for fueling. For whatever reason it was using the blended algorithm. This seems to be not a bug, but slightly misleading name, Pure Alpha-N is essentially blended, but starting with Alpha-N rather than MAP. Therefore I set the Threshold to 9k in the Alpha-N blending dialog.



In addition, I had ego correction active at idle, this results in an idle which falls and rises all the time, setting EGO correction to be active above 1200 worked a treat.

Seven engine rebuild (again)

Well after a disasterous start to the year, it was time for a new engine. The root cause of the failure was the lubrication system possibly caused by a blocked oil cooler.

I got a short block from Jem Engines, its a 711 crossflow bored out to 1700cc, with fully balanced internals. The engine is fitted with ARP con rod and fly wheel bolts. I reused the Kent 244 cam, and burton stage 3 head.

The first thing to do before building anything was to thoroughly clean the head, as the bearing failure had likely resulted in a lot of crud going around the engine, I stripped it completely and used pipe cleaners to go through each oil passage, and cleaned it with gunk degreaser and compressed air.

Afterwards I painted it black (it was blue) to match the block. I used hammerite and so far it seems to be doing the trick.

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Next was time to do the ARP bolts, Eric gave me some ARP Lube, so I torqued them up to 40 ft lbs.

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I can build a crossflow in a couple of hours from memory alone now, I could even remember the number of degrees to set the cam to, although this didn't stop me from making a hash of it the first time and having to re-time the engine after everything was built up.

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I used a competition gasket set from Burton, Eric recons the best way to get a dry seal on the sump is to evo-stick the gasket to the block, then use a little blob of silicon around the rubber seals on the end, and tighten it up gently.

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I tried this, the result was an enormous oil slick on the garage floor after the first drive so I'm back to experimenting with silicon... The engine was back in the car in less than 4 hours, ready to start, or so I thought.

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It fired up first time, but made a noise that left me clutching my wallet.



It turned out that the oil pipe was ever so slightly grazing the con rod bolt, this thankfully was easily fixed with a gentle tap from the hammer and it finally ran smoothly. Getting the sump off in-car is a real pain, however if I loosen off the engine mounts and replace the gearbox->engine bolts with longer ones, I can use a crow bar to seperate the engine from the box about an inch which is enough to get to the rearmost sump bolts.

Sunday, June 6, 2010

Houston, we have a problem (Twice.)

Despite being thrashed incessantly for 4 weeks through morocco resulting in only self inflicted trauma, the seven has now left me stranded by the side of the road twice in 3 weeks. The first through a head-gasket problem, the second due to something big going bang.

The end result is that the block, crank, rods and head are back at Jem Engines, where they will be cleaned, bored/ground/skimmed and balanced, before being sent back for the final build. In preparation for the six hour at mallory I thought I should try to put as many miles on it as possible, sadly following the two dry days in March, there hasn't been much dry weather in Holland since which meant getting out in the car has been difficult at best and not possible the rest of the time.

The rocker cover was full of sludge.

The weather in Western Germany, and Luxembourg was due to be not-wet, so off I set, laptop running auto-tune in the passenger seat, following the Waal/Rhine over the border, then heading cross country towards Trier, the TomTom provides a lovely route, (Set max speed to 40kph) about 4 hours into the drive, somewhere near Aachen, I came into a small town and as I slowed down into traffic, and up to a red light, i noticed the engine was stumbling a little, queue comedy smoke screen as the revs fell to idle and i had to nurse it to keep it from cutting out.

The block got the same treatment

I could feel my hand rushing towards my wallet as I thought of all the possibilities, but when i realized it was just a head-gasket, my next thought was to get it to Holland so I could be recovered directly home. I was about 60km from the dutch border, so I hopped on the Autobahn direction Maastricht and hoped for the best, about 5km later the temperature shot up, so i pulled off, cooled down and poured in 3 liters of water, queue more comedy smoke at idle, but was fine for another 38km where i had to do the same again (Thankfully, i was feeling thirsty earlier.) I made it about 10km over the border before it was out of water again, and managed to pull into a service area to call the ANWB.

The end result looking quite shiny

I then spent 4 hours waiting on the ANWB, who got lost, then sent a guy that couldn't tow it, who got his mate with a beaver tail that didn't fit the car..... In the end it made it on a flat bed, after my ordeal by the side of the road, I was only just able to cope with 3 hours of dutch country music in the truck home.

I put on the manifolds whilst i waited on the bolts to stretch out

The gasket had failed, and was repaired the next day. The following week I was due to take it to the UK and park it up at Paul's house in preparation for Mallory meaning i could fly in in Thursday night, get in the car friday, and all would be fine. I set off, everything was going well, then on the M2 I noticed oil pressure was a little lower than normal, I assumed it was just the thinner oil i'd used post-head gasket, but pulled over to check there was still some in it, there was, so off I set again. I got to my favorite spot on the M25 when there was a funny noise, the engine changed pitch, and overheated whilst i did a 4 lane dash, at this point i noticed i barely had any oil pressure and had that sinking feeling.

I ditched the car, and spent a long time on the phone to the ANWB to try to get recovered, in the mean time i noticed that i was getting enormous blow back out the crank case breather, this was going to be expensive.

The car was then recovered and despite every mechanic trying to tell me it was the fuel pump, or a wiring fault, despite me explaining that this thing called an immobilizer was cutting the connection because they hadnt wiggled the fob.... Its back in holland now, there is a lot of metal floating in the sump, so it looks like a bearing had failed either as a result of low oil pressure, or possibly the root cause. I'll continue stripping it down and hopefully figure it all out soon.

Monday, April 5, 2010

Crossflow Rocker Gaskets

I think I finally found the cause of all the oil leaking everywhere. It seems that its pouring out of the rocker cover flange. I have an alloy one, and its always somewhat awkward to fit it. There is a cork gasket which invariably isnt quite the right shape, when its tightened up, it has a habit of being squeezed out.

To make it easier to fit, I usually use copious amounts of loctite gasket sealer which bonds the cork gasket to the rocker cover, making it easier to assemble. It seems that this is still not good enough, I've always been aware of a small amount of oil on top of the inlet manifold, which I assumed was mainly runoff from when I'd filled it, however on closer inspection there is actually quite a lot of oil running out and down the block.

I've since dispense with the cork gasket all together, and cleaned the alloy back to bare metal. I've applied a fair bit of loctite 5922 flange sealer, hopefully this will be the end of the leakage. On a better note, this seems to be the only leak that I actually have, although its hard to say as it gets everywhere.

Wednesday, December 30, 2009

Engine Rebuild

I stripped the crossflow into component form, leaving the pistons and crank shaft well alone though. The bores are showing no signs of wear, but there was rather a lot of carbon deposits. I de-coked the engine as best I could and cleaned it thoroughly including the oil channels and water galleries. The kent 244 cam was installed and timed, using a timing disk.

The short block and components ready for rebuild

Quite a lot of crap on the inside, but no leaky head gasket, bores are in good shape.

I'm starting to see mild valve seat recession which is alarming, so I expect that by this time next year I will need to have new seats fitted, at the same time I will fit hardened seats which mean I can run pure unleaded. I may use this as a chance to rebuild one of the spare blocks and heads to give me a running spare.

There is some valve seat recession present, next year i'll probably get the head converted to unleaded

I fitted new valve springs and fitted stem seals, the originals do not fit as they foul the internal spring, ones from an MG metro do fit however so these were installed. I fitted a new rear oil seal and gaskets and should hopefully now have a leak free engine.

All bolts where assembled with threadlock. I also fitted a T-piece in the top cooling hose to insert the Coolant temperature sensor for the microsquirt box.

Alternator bracket lockwired as well as thread locked - Course threads are a real pain...

I must now weld up the sump, or find a new one before putting it back in the car. Once in the car i'll need to run it at 2500rpm for about 20 minutes to run in the new cam, and at the same torque down the head again.

Thursday, December 10, 2009

Floor Painted

After Morocco, the car is in need of some love. Half the Sahara seems to be inside of the car, so as the weather is cold and wet, I've started with a proper clean.

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I removed the seat belts and anything else in the way, got out the wire brush and grinder and cleaned up all the floor back to painted metal, and in some places back to the metal itself. Two coats of hammerite later its looking pretty good.

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The seats were maukit, so I cleaned them up with detergent, and some vinyl polish, they came up pretty well.

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I Also painted the roll bar, and a few other bits of the chassis which were exposed to daylight and have faded a little.

Sunday, December 6, 2009

Todo

Seven
Engine
  • Fit and reinforce engine mounts to ensure they wont fail in the same way again.
  • Fix or replace sump, either shorten the existing one or just stick a non-battered one on, whichever is easiest. Potentially make a sump guard.
  • Change crank shaft end seal for one that doesn't let oil pour out - some people find a bit of oil acceptable but I find it embarrassing so it needs to be sorted out.
  • Since the engine will be out I want to change the cam, I'm relatively happy with the piper 285 cam, it has lots of torque from low RPM, and reasonable high end power so changing it is a bit of a gamble. I've decided on the kent 244 cam, its a high lift cam, and should give improved top end power, with a loss of low end torque. To compensate I'm going to be running fuel injection, which should enable better fueling at low RPM and pull the torque up a little.
  • Remove cylinder head, de-coke, and examine engine for wear- I'm interested to see the state of the valve seats after 7000 miles using additive, its also a good time to change the head gasket, its got pretty hot a couple of times, and I'd like to ensure there are no failures in the gasket.
Fueling
  • Fit the Mega squirt (Microsquirt) for full fuel injection.
  • Buy and Fit a larger fuel tank - 20 liters just isn't going to cut it, I feel I'm constantly refueling.
  • Fit larger fuel lines with a return to the tank, for fuel injection I will need a fuel return, standard sizes seem to be based around 10mm for fuel feed, rather than 8.
  • Fit the in line fuel filter and buy and fit injection pump
  • Fit the throttle bodies from the GSXR 750
  • Permanently install the wide-band LC-1
Bodywork
  • Remove the scratches from the bonnet, remove the nuts and bond it into one single piece rather than the Sort out the bodywork, fill up the hole where the aerocatch doesn't fit due to the intake system and make it orange again.
  • Make a new boot box, i'll need this because the fuel tank will be a different shape, and wont fit within the current one, it is also starting to rot a little and needs to be made out of something non-wooden.
  • Fit a new drivers side mirror as the current one is beyond service.
  • Paint the interior where the paint has worn and touch up the rest of the car as appropriate.
  • Make and fit ally floor covers
Electrical
  • Accessory wiring needs to be rewired, with heavier wire, and a smaller, dedicated fuse.
  • Decide on a data logging solution that is compatible with the mega squirt
Other
  • APK is due in December.
Fury
  • Fit alcantara cloth I got for the interior
  • Finish dashboard buck and make dash
  • Wire engine completely
  • Fit passenger seat and seat belt
  • Paint and refit roll over bar
  • Make car bottom from ali and fit
  • Fit the prop shafts with grade 12 bolts
  • Fit steering wheel and boss
  • Figure out the dash layout, and the logic design for the indicators on the steering wheel.
  • Figure out the appropriate adaptors needed for the oil pressure/temp senders
  • Decide on the dat logger I want to use
  • Get the rear lights and wire the rest of the car
Garage
  • Fit car ramp, wire in new motor or inverter as required
  • Enlarge mezzanine as appropriate.
  • Do a full clear out post-sanding.


Wednesday, October 14, 2009

From Goodwood to the Sahara

From Goodwood to the Sahara

I managed to blag a few weeks off work, and I've been desperate to spend some quality time in the car, sure we took it to Le Mans this year, and regular long day trips and the odd weekend away, but what I really craved was a driving holiday.
Combine that with a certain urge to visit Morocco and climb Jebel Toubkhal and you have all the makings of an adventure.

The start of the trip coincided with the Goodwood revival, Ivonne and a group of ferrari owners were heading over together and I was invited to join them for the weekend, so I really was leaving in style. I was a little nervous about this, I had images of owners of pristinely polished and meticulously serviced Ferraris staring frustratedly at me whilst I tried to make my car start by the side of a particularly wet motor way, but actually it couldn't have been further from the reality.

I didn't get off to a very good start however, I managed to sleep in, promptly drove like a maniac towards belgium to catch up with the group, then ran out of fuel about 1km from the petrol station to discover that in my haste to get underway i'd put the empty jerry can in the back, and not the one with some spare fuel in. No major delay, just embarrassing.

The belgians didnt want us entering so raised all the bridges

We stopped off in Brugge for a spot of breakfast, despite the belgians doing their best to keep us out by raising all the bridges for no apparent reason. Breakfasted we set off for the Eurostar and then on to our hotel in Canterbury. The next few days were spent at Goodwood enjoying the racing, people and the Champagne which seemed to be flowing rather well. The highlights for me were the 1960's GT and LMP cars racing, these cars are just beautiful, not just the shape, but the sound as they drive passed. Other highlights included the Avro Vulcan Bomber, it really is an amazing piece of engineering, the noise it makes is something to behold, but for such a big aircraft it seems to be incredibly agile.

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Goodwood is incredibly well done, with full access to the paddock most of the weekend, the air displays, racing and everybody in period theme, the racing almost becomes just a backdrop. At the end we tried our luck for a few pictures of the cars outside Goodwood house, we had hoped to be a bit closer, but Jeeves was keeping a rather watchful eye over the driveway near the house, and I suspect the odd shotgun within reach to keep the peasants at bay so we found a nice stretch of lawn just out of range.

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The car was behaving more or less acceptably, but I noticed it was getting a bit hot on the sunday for no good reason, I topped up the oil and water to no avail, then the next day it was fine again, so put it down to the warm weather. I sailed from Portsmouth to La Havre, and from there the real holiday begins.

A bridge somewhere in france

From La Havre, I set the TomTom to limited speed of 40km/h and the destination Le Mans, the weather was overcast but dry, the roads pretty quiet, and the countryside beautiful, i pretty much didnt see a big road or town until just out side le mans where I started to recognise things, so took a detour around the public part of the le mans track, you can drive down the mulsanne straight, and the arnage bends, I thought it would be rude to pass up an oppertunity not to.

The end result was a big mess

From there I dialled in Orleans, then Pau, I camped the night in the Gascogne national park, I stopped for fuel and I noticed whilst queueing up that the temperature was getting a bit high and there was a bit of a rattle form the front of the car, this was not good, so I did some investigating at the camp site.

There were two rattles, the first was the bolt that holts the tensioner for the alternator had come loose, it then vibrates out and hits the water pump pulley, where it rattles and bounces around. I tried to tighten it up, but to no avail, so I took the pulley off to discover the bolt had snapped, my heart sank a little at this point as the bolt is UNC (Almost impossible to find easily in continental europe.) and of course the remainder would require me to remove the waterpump, and possibly drill out the remaining bits.

I know from experience that the waterpump can be somewhat leaky when a bolt is so much as wiggled, let alone removed, however the only symptom so far was that the water is being pushed out into the expansion tank, and air being sucked back in from somewhere else. I decided to leave it until it properly failed and then fix it. I had brought with me a full gasket set, but obviously would rather avoid messing around with the pump.

I then tightened up the alternator pivot bolts as tight as I could, and removed the tensioner bracket, I also know from experience that this will work for a finite period of time before the bolts start to loosen a little and you get a squeal from the belt.

The next problem was the fan, the fan blade assembly is held onto the motor by a bolt, and a square drive gear, I'm not sure which failed first, but the drive gear had shredded the hole in the fan blade assembly and rounded all the threads off the bolt, the nut was nowhere to be seen.

I had horrible visions of melting down on my way to Santiago de compostella, but figured thats what ANWB coverage is for. This was not the place to be looking for spares, so I decided to carry on the next day as planned, avoid cities (Already the plan.) drive in later at night and park up somewhere I could fit a replacement.

Heading down the spanish side of the col, road much smoother, brakes smell *bad*

The next days drive was over the col from Saint Etienne de Baigorry in France to Erratzu in Spain, its a wonderful drive, tight twisty bends, great sweeping vistas, reasonable road surface, the odd man and his donkey, and not much else for many many mountain miles. The drive was blissful, the temparature stayed under control despite spending a good 20 minutes or so above 5000rpm, 2nd gear, 3rd gear, brake brake brake, 2nd gear, turn, and repeat.

Its quite a climb

The rest of the day was a bit of a slog into Santiago, I arrived around 9pm, and parked up at the first parking garage within walking distance of the hotel, and went out for dinner. The next day I phoned rally design who were sadly about as much use as a chocolate kettle. That is twice in a row i've had bad service from them despite spending many thousands of pounds with them over the last year. Instead Burton power came through and sent me out a kenlowe fan next day guaranteed delivery which turned up the next afternoon complete with fitting kits and quick fitting kits. Its a bit bigger than the pacet one so i had to bodge it a bit, but it was mounted, wired in, and worked a treat.

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From Santiago it was off to Lisbon for what was supposed to be just 2 days as I'd spent a bit longer in Santiago, but I spent at least 3 days there having a great time. I went out to Estoril, and watched some motorbike racing, before heading off to Seville for a couple of days.

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En route to Seville the additional weight of the fan caused a stress fracture in the radiator mount so I had to stop to rethink that, and patch it up. The road was pretty nice, a little congested to begin with then some nice twisty sections in the dark before arriving into the traffic nightmare that is downtown seville.

The first breakdown of the day

From seville it was the boat from Algeceres into Ceuta, and from there into Morocco. The spanish side is as you would expect, I got singled out by a rather nice border guard who wanted to check it really was my car, they checked the VIN number and all the documents including APK and Greencard. Paperwork at the Moroccan border was minimal, and the touts not too annoying, you simply drive up to the window, get your passport stamped - you need your entry card filled in before this point, as a foreigner you don't have a C.I.D. number but you must fill in everything else or at least attempt to, else the guy will get a bit stroppy.

After your immigrated, its time for your car, you will get a form from the window you fill in the info from your passport, registration document, and stamp from moroccan immigration, they stamp all three copies and give it back to you, from there you hand the top copy to the Duane 10 meters later and drive out, keep it all handy as you have to wave it at the policeman at the end of the border area about 50 meters later.

I was now in Morocco, somewhat nervous but very very happy. That was 3500km and I was still in one piece. More importantly so was the car. The mediteranian coast of morocco is pretty much like europe, and I started my drive south towards Fes, road signs are minimal but there arent many roads so its pretty easy to navigate.

Once it got properly dark and the roads became a little less of a pedestrian zone I picked up the pace, enjoying the bends, working the car a little harder, overtaking when I could, then all of a sudden I saw a white wandy thing waving in the middle of the road, it took me a long time to realize it was a police checkpoint and throw on the brakes.

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The poor chap standing in the middle of the road with no reflective bits, dressed in black with just a little wand to wave must have needed a new pair of underpants. Needless to say he wasn't best pleased, he told me to move to the right, get out the car and give him my papers, experience told me this was going to be a) long b) expensive, or c) all of the above. Actually once we'd both recovered form the surprise he was pretty friendly asking about the car, where I came from, did I like Morocco, etc etc, and this was pretty much the standard conversation from then on with any of the authorities. That night I camped by the side of a country road over night and got up at sunrise the next day.

Camping by the roadside

From Ifrane I headed east over the midi-atlas, south a bit, then up what was supposed to be a metalled road towards tamagourt and then khenifra, but it got pretty knarly, recent rain had left the infrastructure pretty much destroyed. I went through water crossings that had water coming in the drain holes, mud that was up to the floor, and at one point had to clear the road of a rock slide to continue. It was great fun, but slow progress.

I'm caked

In the end I had to stop for some fuel, so asked about the roads, the best road apparently was down towards the gorges, this was great, as I had actually wanted to do this but as it was piste I had avoided it. The views were amazing, and it was deserted, the road was being constructed most of the way so it was packed gravel wit the odd bit of new road covering. I Stayed the night in the Todra gorge and the next day headed towards Zagora taking the shortcut recommended by the hotel.

The road is here somewhere

Top of the gorge

rutty but at least its dry

This is where disaster struck, I noticed the temperature rising, and a strange smell of fuel, bearing in mind its the desert, and obviously rather hot i slowed down to a bit, and still the temperature started to climb, not much just not the standard 82C that I normally see, I decided it was time to pull over and investigate. When I got out it was obvious what the problem was, there was oil everywhere.

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This would be bad....

The engine mount had failed, causing the engine to drop down at an angle, crushing the oil filter in the process and putting a crack in the sump. An hour or so went by as I rationed my water and tried to find shade in the midday sun. I thought I was going mad as a bloke on a bike cycled passed. Ca Va? he said, i explained in my best berber arabic that my automatic camel was broken and needed some assistance. Desole, came the response. He was prepared to take my cash and cycle into a city and come back with a rope and a tractor, but I turned him down, he was heading the wrong way, and I knew there was a town about 15km away so figured a bus or truck must go passed fairly soon.

Not long later a van came passed and we agreed a price to tow me to a mechanic, he went and got a rope and his friend and I talked and gestured about my trip and my dilema. An hour later I was at a place somebody described as a mechanics workshop, the only tool I saw as an improvised hammer, and as somebody once told me, when your only tool is a hammer, every problem starts to look like a nail.

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They got a new filter, and procedeed to weld my engine mount (The rubber had failed) back together, of course they didnt bother checking alignment or even if it was on the right way, afterall, thats what hammers are for. They didnt want to weld the sump as it was too thin, their solution was more oil, but in the end I managed to screw a self tapping screw with a big washer and lots of glue into the what turned out to be tiny crack in the sump, and I was on my way.

Considering it cost less than twenty euros it was a bit of a bargain, even if the two half-tacks on the engine mount only lasted a few hundred kilometers, i was just happy to be on the road again and away from mallet wielding car butchers.

I arrived in Zagora quite late and the first person who approached me was a mechanic on a motorbike which was great, as I was in need of some serious spanner love. Zagora is sandbasher heaven, and this garage had real tools, mechanics that knew how to use them, and some charm.

Common Failure point

My cycle wing mount had failed just as I came into the city, so we removed both sides welded them both up with a bit of reinforcement for good measure, then welded up the radiator mount, it will fail again, but it will certainly get me home.

Cycle Wing Repairs

They then washed and cleaned the car whilst I went off riding camels and hiking in the desert, and two days later my car was almost as good as new. From Zagora it was north towards Imlil, it wasnt a long drive or so I thought, however on arriving in Oarzazate, the engine mount failed again, so this time I drove right into the blacksmiths shop, pulled the engine back up to its right height, and got a proper repair done, this time the guy welded all 4 sides of the mount solid and reinforced it with some bracing, this WILL get me home. In fact I'll be lucky if I can get it out again.

Post wash and Wax in Zagora

Almost everywhere I went in Morocco the people were amazingly friendly, everybody loved the car, everybody waves, and you wave back, in the country, thats just the way it goes, you slow down for a passing car, you wave, say hello, sometimes have a chat, and drive off again. Most police checkpoints I got pulled in, not out of rudeness as you might expect but out of curiosity, sometimes to justify the interruption they would ask for a token bit of paperwork like a passport or drivers license, but it was clear they just wanted to know about the car, how fast is it? How much did it cost? What model is it? What type of engine? I was always getting help on directions even if I didn't need it, it was almost the polar opposite of what I had expected here for some reason.

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Twenty minutes down the road there was puff of smoke out of the dashboard, before I even knew what was happening I had the isolator key removed in one hand and the fire extinguisher armed in the other, steering with my knee i pulled over and threw out the anchor to discover that the mike for the camera had melted then shorted out due to the heat, and that the fuse had shorted so there was no major issue anyway.

I also discovered that my phone had melted in the heat, you just don't realise how hot it gets when your driving as the cool (42C) breeze stops you from saturating yourself in sweat, its only when you get back in the car and touch something metalic you realise just how much heat is soaked up.

On the map Imlil was about 8km south of Jebel Toubkhal, 30km form the main road along a piste, Geert-Jan has been here and assured me that its along a metalled road so I just assumed the map was out of date and off I went. I kept going until the road petered out and the atlas started to look pretty tame. "Imlil?" I asked the locals who gave me a blank stare, evidently this was not where i needed to be. I drove back to the main road, (It was a nice drive.) refuelled, and looked at the map again. Imagine my surprise to find two imlils, the other the real Imlil is about 20km as the crow flies from the fake Imlil, however its the other side of the Atlas and about 250km drive away.

Tizi n'Tichka

I set off, blasted through the Tizi'n'Tichka which is an amazing bit of road, its just switchback after switchback after switchback the whole way, reasonable road surface and a great oppertunity to test the brakes. I thrashed the car all the way up and down and loved every second of it. From there its just a long slog back to Marakkesh as I managed to miss the turning, and decided it would be easier to pick it up from Marakesh rather than hunt around for the correct village here.

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I got into marakesh traffic and turned the fan on, a few minutes later the temperature was at 105C, things where not looking good, i figured the pump had failed and looked for somewhere deserted to pull into, took the bonnet off and realised i couldnt hear the fan spinning, fortunatly it the cable had snapped at the earth point , this was a simple crimp job and i was on my away again.

I started winding my way back up the atlas, it was dark but the roads were great, and suddenly I reached the end of the road, a ski resort in the high atlas, the map indicated a 10km drive over to Imlil, the guy who lived there indicated a 25km return trip, a left, a right another left just as you arrive in marakesh and off you go again. My heart sank, i was tired, i had a throat and ear infection, it was late and I wanted to be in bed, but if I wanted to climb up the mountain in this trip I had to be in Imlil and start the hike the next day so off I went. I saw a sign for Asni and took that, and ended up in a maze of gravelly backroads for what seemed like eternity, in the moonlight i could see road, no barrier and a steep drop.

After driving for another 90 minutes, i arrived in Asni, and then the trip up to Imlil was relatively easy. By 2AM I was all packed for the next day, a quick vomiting session, shower, then bed and at 7am I started the climb. I felt terrible to the point of passing out so decided to try for the summit in one day since I expected to be pretty much bed ridden the following day, so at 4.30pm I was sitting on the top, not a soul in sight taking in the view, it was wonderful. By 6pm I was back in the refuge trying to keep down some warm soup before passing out in bed. It was worth every frozen footstep to the top.

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From Imlil the next day I took the fast route north, I had hoped that I could get to Ceuta and possibly even into mainland spain that day, but I got lost and ended up in Tanger and the border crossing back into spain took an eternity. You drive up, and if you have the right car, you just drive through, if your not from Ceuta, you have to do the paperwork in advance, this involves standing at window 4, which has nobody there, you then go to another window and get yelled at for 20 minutes or so until you explain that you are at window four but nobody else is. Then Mr Jobsworth arrives and tells you to fill in a form, your pen doesnt work because its melted obviously, and he wont lend you one of the 50 or so littered around his desk.

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You have a chat with another friendly guard who gives you a pen, fill it in, and get yelled at for not understanding arabic. Passport stamped you walk through the border, and its back to normal. The guards are interested in your car for the right reasons and i spent about 20 minutes talking about the car how i built it, how fast it goes, where iv'e been, did i like marocco and suddenly you forget about the numpty who wont share his pens.

On returning to spain I decided to lord it up for a night so stayed in a posh hotel on Plaza de Africa, the bar was open so I gulped down a few beers and all the nibbles they had, chips, jamon, olives, and some other meaty things and headed out for a walk, my legs were feeling in good shape, and I felt a lot more human than the day before, so i celebrated by eating the greasiest, nastiest, spiciest hamburger I could find. It was also the only hamburger I could find, and it tasted amazing. I then washed it down with some more cold beers and went for the longest hottest shower of my life only to discover i wasnt as tanned as I thought i was.

I had another walk around in the morning before getting the boat back to mainland spain, from there it really was just a case of getting home, i drove up the spanish coast staying in Malaga, then Sitges before crossing into france breaking down on the only bit of peage i'd driven. It was pouring down, so i decided the best route forward was going to be the fastest smoothest one which would hopefully allow me to overtake the weather. It was dark and suddenly the engine cut out completely, not in the kind of way that suggests its going to be fixable, just completely dead.

With plenty of fuel, and no spark, I spent about 30 minute at the side of the road checking the obvious, has the coil pack got power? Fuse blown? Wire lose? Nothing, i removed the megajolt to see if the EDIS unit would fire and got nothing. The taco didnt move indicating it was something ECU related rather than coil related so i decided to call it a day, my phone was dead so i walked off to the booth and called out the recovery truck.

I figured i had nothing to loose by keep looking for the fault and about 30 minutes later I found the culprit, the wire to the VR sensor on the trigger wheel had broken at the soldered joint. I figured I was still doomed as there is no way I was going to be able to fix it as I couldnt get the pin out to crimp it back together, and even if I could it was way bigger than hte bit of wire and wouldnt fit in the crimps I had.

Never say never, I cut the connector to bits exposing the pin, fitted the largest crimp I had over it, and crimped it tightly, then fited a medium size crimp inside that oen, and a smaller one inside the medium one. I then pushed the wire inside the little crimp, crimped it all as tight as I could, cable tied it to stop it vibrating and it started first time. Just in time for the recovery truck to arrive and charge me for a call out. Oh well.

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From then on it was plain sailing, damp, but not to wet I arrived back in Utrecht via Eperney to stock up on some champagne, with a list of repairs and improvements and a huge grin on my face.

Back home after 6500 Miles