I am quite happy to say that I have managed to get quite a bit of work finished on this little wagon. With the evenings being brighter and warmer and having a new dose of enthusiasm I have spent more time on it and its been fun.
So where was I last update. Lets start with the doors. I knew they had rust but not too bad and in places that’s easy to get to. I have been putting off repairing them so now is the time after having just finished the last few bits on the tailgate (hatch..)
Luckily the rust was mainly on the outer skin wrapping over the inner strengthening panels that the hinges are welded to. I cut it away and let in some nice new thick sheet. I actually ground back the welds afterwards because it it made sense to have it all finished properly in a place that is hard to get to once the doors are back on. Plus the seals, speaking of which I will need to get some decent second hand ones with the originals having fallen apart, will need a good smooth surface to squash against.
![Image](https://s25.postimg.org/79yjwh2r3/P1110116.jpg)
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There was minimal rust along the inner bottom of one door and they fixed up well. Really glad they are in good condition otherwise with minimal dents on the outside (just dented enough I say..) While I was working on them I also had one of those ‘expecting it to be a *Bleep* but it was actually easy’ moments when I had to remove a broken screw from a window winder stub. The screw was small, broken unevenly and I sure that Id not be able to drill it central enough. But I did, it worked and I was happy..
![Image](https://s25.postimg.org/n0jmq3m0f/P1110125.jpg)
With the doors repaired and the repairs painted over I put them aside and started on the wiring. I enjoy wiring and have always planned to tidy all the original stuff up. I got carried away and its now pretty well hidden from view. I added some extra wires for the fan etc and decided to run the main loom out of sight via a hole I added in the tunnel. The original bulkhead grommet worked perfectly.
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Once I started hiding things I got even more carried away. I disliked the look of the fan wires running externally along the top of the bulkhead so they were carefully re-routed then back through the heater box and through another added hole.
The main loom sorted back through inside the car and I was happy with it all.
Onto the heater hoses. I first fitted them up in the original positions. Oh dear. No, no ,no.. this will not suffice !…
![Image](https://s25.postimg.org/5j6c3i6gf/P1110135.jpg)
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Damn they are ugly hoses, just running over the engine like an afterthought, looking like a scaled up version of a badly designed Lego tecnics kit with poorly scaled pneumatics. Nup. No sir..I don’t like it!
So I rummaged through my always handy supply of random hoses and found a few Mazda items that will help in my quest for neatness, a Toyota bottom hose and a ideal tee piece. I also found a heater pipe from the Crysler Northstar quadcam V8 I have been gifted (another story…). Still not enough pieces to complete my puzzle.
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Back to the wreckers then…
I love going to wreckers, especially when they let you roam about by yourself and get your own bits, a rare thing these days with so many OSH rules. Luckily Hannah enjoys it too because she was along for this sortee. We found a variety of hoses from a Datsun something, a Mitsubishi Mirage, a Honda Shuttle and also scored an ideal inline heater valve from said Honda. A few hose clips and other handy bits. All this for $10
![Image](https://s25.postimg.org/gb8hwcban/P1110145.jpg)
Back home and I assembled my scavenged findings together and came up with a design. It worked out fine except for one thing.. the heater valve works backwards. Hot is cold and vice versa. Luckily my other Viva, with its Chevette sourced heater valve is exactly the same. So no confusion for us.. just everyone else..
After finishing them I noticed my exhaust was not yet connected to the manifold. Then I discovered holes. Bugger! So old towels out to protect things and I carefully welded in some repairs. I am a bit upset in that the blobby welds might well restrict things and lose me a pony or two. However I shall learn to deal with this.
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Then on to the breather and brake servo hoses. I have decent PCV valve to use and some pipe now. But nothing matches. Out with my stock of alloy bits and I worked out a plan using my 1/8th bsp taps. I machined up an adaptor and it worked a treat.
![Image](https://s25.postimg.org/uo1xunvan/P1110150.jpg)
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With that lot finished and looking a lot neater it was now it was time to sort out the throttle pedal to carb interface system. I am using a HC Viva floor mounted pedal like in Viva one. The original top mounted pedal system uses rods and is..ugly. I copied the design of cable clamp and pedal mount from Viva one. Noted how much cable pull was offered by the pedal. Did some maths and worked out the diameter of pully needed. Then I machined up a pully from a lump of alloy on the trusty old, leaky, English lathe.
Cable clamp..
![Image](https://s25.postimg.org/e5e71u7u7/P1110156.jpg)
Measure the cable pull..
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Pedal mounting..
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A leaky (because English) old lathe and a lump of alloy..
![Image](https://s25.postimg.org/j5g8nj2un/P1110157.jpg)
A new working pulley..
![Image](https://s25.postimg.org/sfscr2dkf/P1110160.jpg)
Made a new cable bracket and used some old bike barrel adjuster. It was an easy enough job but just time and I’m glad its done. I won’t mount it yet as some wiring to do for the starter solenoid yet to be done.
But I’m not far from firing the little 1159cc block of fury up and I’m quite excited.
Here’s a photo of the completed heater hose layout. I’m much happier with this..
![Image](https://s25.postimg.org/4rcuvsh0v/P1110162.jpg)
Back to the shed now.