|Not too bad, but now is the chance to tidy up|
|Auxiliary fuse box and headlight relays|
|Facet pump with its filter mounted under floor|
The front bumper had the usual TR7 droop problem and I found the rubber mounting blocks had failed completely allowing the bumper to be waggled quite a lot by finger pressure alone. There is masses of stuff written about ways to repair or replace these mounting blocks but the alternative is to use the bumper from a TR7 Coupe which doesn't have them. Its all about the original design of the cars back in the 1970's when they decided to include a "harmonic damper" on the DHC models to improve ride quality on country roads and which also includes quite large blocks of cast iron in the ends of the bumper. Simplest solution is to simply use the bumper off a Coupe which bolts straight onto the car and my old red car just happened to have Coupe bumper. Not any more - its now on the new one!
|No droop after Coupe bumper fitted.|
Testing the headlights and sidelights revealed the next problems. The drivers side headlight suddenly didn't work on main beam, but dip was OK. I was concerned my new relays were at fault but I found a nasty old repair in the wiring, its was wonder it had ever worked at all.
Next thing was the sidelights and dash lighting was intermittent. This fault was more illusive and took a while to locate but was finally traced to the fuse box. Sidelights and dash lighting are fed from the same fuse and I had blown it when I was messing with fitting the sidelights in the new bumper. I had replaced the fuse but this turned out to be the cause of the problem. It was a brand new shiny one I had recently bought but although it was the correct rating and length the diameter was about 0.020" smaller than the original Lucas one. Doesn't sound much but it meant the clips in the fuse box were slightly loose causing a bad and intermittent contact. I replaced it with an old dusty Lucas one and the fault was fixed!
Motto: new shiny stuff is not always good.
Another little job to do before the engine went in was to replace the foam seal on the fresh air intake to the heater. Its a bit fiddly to do but not so bad when you can stand in the engine bay to work! I just scraped off all the old crumbly foam and then glued some new stuff on. The new foam I used is about 2mm thick and often used to line the drawers in your toolbox but seemed to be just the thing here. Putting the vent to the "closed" position held it in place whilst the adhesive set. Now when I close the vent it actually stops cold air coming into the car when you don't want it. Excellent. At the same time I did the similar job on the fascia fresh air vents as well. They also work properly now.