The Story of Build 002

Part 7 - 2012


If I'm totally honest, I had stalled a bit with getting Build 002
back on the road after receiving all the interior trim back.
Having been sat for a while, he refused to start.
In March 2012 we received a visit from Brian Hollins.
After lunch, Brian nagged me into lifting the bonnet to take a look.
Much to my amazement, within 20 seconds he had found the fault - not the
notoriously unreliable Tickford accessory fuse box, but a blown fuse
that I hadn't noticed.........embarrassing or what!
The fuse that supplies the AFT box should be a white 8A, but Brian immediately
noticed that someone had fitted a little yellow 5A fuse by mistake
at some point in the past and unbelievably, the car had been
running with that since I had bought him back!
he 5A fuse must have blown the last time I tried to start the car!


Brian Hollins with the open bonnet


We had to crank the engine for about a minute to get it going,
but then it ran as sweet as ever.
Not bad considering that the petrol was a few years old too.


Smiling like an idiot, but you get the idea that I was ever-so-slightly pleased!


I now have the spring and summer to get an MOT and finish some detailing.
Still have to get the new interior fitted as well.
There is a deadline as Build 002 is booked for the Rare Breeds Show at
Haynes Motor Museum on Sunday 2nd September 2012 with
several other members of the Tickford Owners Club.



20th July 2012

Finally had an opportunity to get 002 off the ramps today where he has spent
most of the last three years.
Fired-up no problem, but definitely isn't idling smoothly and I suspect there might
be some water in the old fuel, so off to Halfords tomorrow for some
Wynn's Dry Fuel additive (thanks for the tip Brian).
The tank is only 1/4 full at present, so I must top it up with a fresh supply of petrol.
Gave him a quick wash with Autoglym shampoo and the paintwork has come up
quite nicely after drying off with a chamois.
Amazingly, even after standing still for so long, the brakes haven't totally seized.
All four discs are quite rusty though and need replacing.
Couldn't resist taking him for a quick spin down the road - would you believe,
the brakes seem to be working ok!
Still had a bit of time before it got dark, so I made a start on installing the
 new interior - dashboard surround and steering wheel.
 Also temporarily connected the new boost gauge just to check it was working.

The MOT is booked for a week's time.


Ready to roll...............
The paintwork has come up quite nicely
Battery on charge using an Optimate battery optimiser
Not as clean as I would like under here!
I'm not saying Tickford Capris run hot under the bonnet, but!
The bolt securing the top alternator bracket was almost completely
undone - don't know how long it had been like this
Now that I no longer have the Zemco cruise control and trip computer, this
RS1600i fuel flow sensor needs to leave the engine bay
The re-trimmed dashboard surround and steering wheel look great
And the boost gauge works


27th July 2012
I took Build 002 down to our local garage and to my delight,
he sailed through the MOT.
How many modern cars will be able to reach the age of 30, sit in a garden for three
years and then pass without a single advisory!
The MOT tester observed that the notoriously unreliable Tickford rear brakes
were working better than the standard 2.8i front ones!
To be fair, the front brakes were a little seized and binding, but the garage
kindly took the front wheels off and eventually managed to
coax the pads out for a thorough clean.
 Emissions only just met the MOT standard, but then the car hasn't even had a
 tune-up yet, so I'm not going to worry too much.


In the MOT testing bay


Next job will be to take 002 over to Brian Hollins at the beginning of August
and spend a couple of days carrying out a full service.
 Then the rest of the new interior goes in and we are all ok for the Haynes show.
To celebrate, I put his original black pepperpot wheels on and added a bit
of bling to the plenum chamber!


Black wheels just look right on this car
Polished plenum chamber cover from Mirage Stainless Steel Styling
that I bought a while ago, but never got around to fitting


9th August 2012
Just returned from a 4-day stay with Brian Hollins over in Surrey.
 He put his extremely well equipped garage at my disposal and
 we both had a great time going over 002 in detail.
The drive to Surrey was the furthest 002 had driven for quite a few
years, so I took it very easy on the accelerator and brakes just to
make sure that we arrived under our own steam and not
on the back of an AA recovery truck.
Prior to leaving home, I discovered that the air flow plate on the
Bosch fuel distribution meter was quite dirty and sticky.
Some carb cleaner and a quick wipe around definitely made a slight
improvement to the rough idling.


This should be clean and shiny!


The idle was even better by the time I reached Brian's.
This was no doubt mainly due to the fact that the car had just driven a
distance, but maybe also because the tank was running a mixture of
fresh 97 octane petrol, Wynn's Dry Fuel, Wynn's Injector Cleaner
and Castrol ValveMaster Octane Booster - what a cocktail!


Build 002 awaiting attention in Brian's garage


First jobs were replacing the entire crankcase ventilation system
and fitting new charge air hoses.
The crankcase ventilation consists of a PCV valve in the right hand
 rocker cover that splits two ways via a T-piece and then each
split has a non-return valve before feeding into:
(i) the plenum chamber
(ii) the air intake to the turbo
I had noticed that my turbo was smoking a bit around the edge
 and this was simply due to the fact that one of the
non-return valves was blocked solid.
This increased crankcase pressure and forced oil past
the seals in the turbo.
As good practice, we also replaced the oil filler cap as this
has a gauze breather built into the lid.


Blocked valve and very tired hoses Shiny new ones


Removing the old charge air hoses proved to be quite an experience.
The 2.8i throttle body has a 70mm opening, but Tickford's big polished
charge air pipe is only 65mm.
Because it is such a nightmare to stretch the thick black connecting hose
over the throttle body, it is normal practice to leave it in place
and remove the polished pipe instead.
Would it come off? Not in a million years!


Notice the bulge where my charge air pipe connects to the rubber hose


Turned out that my charge air pipe had a flared end, but luckily Brian
had a replacement in stock.
It opened a very interesting can of worms - 002 was built in a limited
pre-production run of four cars at Blakelands, prior to
the start of the main production at Bedworth.
 Going through 002 and comparing him to Brian's own later car highlighted
an almost endless list of subtle differences in the way things
were bolted or routed.
Guess it just makes Build002 even more unique!


The standard Tickford pipe is bent slightly differently, has polished mounts for the 7th injector.......and no flange!


If anyone ever asks you to fit a new hose to their throttle body,
politely decline and run in the opposite direction!
 An hour later with several pints of boiling water, a whole can of Silicone
 spray and various screwdrivers, interspersed with uncontrollable
outbursts of bad language and the new one was on!
To be fair, Brian did his bit too - laboriously spending half an hour
gently filing off the lip on the throttle housing to buy
us an extra couple of millimetres.


"Just fit a new hose" Brian said!


We carried out Brian's recommended modifications for the air intake, fuel lines
and vacuum distribution hoses.
The large black corrugated air hose that feeds the air filter under the front wing is a
standard Aston Martin part and too long for the job.
Instead of having cold air rammed in to it  from the slot in the front spoiler
 as Tickford intended, it tends to suck warm air from
 around the bottom of the radiator.
We shortened and re-routed it so that it works properly now.
All the main fuel lines to and from the air flow meter were replaced with a
mixture of 6mm and 8mm hoses, brass reducers and T-pieces.
The hose to the 7th injector was dangerously perished and needed sorting
immediately - a spray of high pressure petrol directly onto an exhaust
manifold at maximum boost is seldom recommended!


All the new fuel hosing looks much nicer..........and safer!


The engine management system and boost gauge now have their own
 independent vacuum supplies from the plenum chamber - 6mm for
the AFT box and fuel enrichment computer split via a T-piece,
 with 4mm for the boost gauge.


The fitting on the AFT box is really for a 4mm hose, so I have temporarily secured
 the larger 6mm hose with a cable tie - reducer and length of 4mm hose to follow


I had already upgraded the air filter to a K&N and changed the spark plugs, HT leads
and fuel filter prior to the journey, but Brian suggested that we also replace
the coil, distributor cap and rotor arm.
The 30 year old rotor arm eventually came off as a kit of parts, distributed all
over the garage floor.
The original had a 6100rpm mechanical rev limiter built into it, but the current
 replacements are set to 6200rpm - not going to lose any sleep over it.


From Brian's experience, a nice new coil always improves things as Tickford
Capris are very fussy about their HT voltage


I had been troubled by squeaky fan belts ever since I reacquired 002 back in 2008.
There are a pair of drive belts that run between the crank, water pump and
 alternator - one of these had no teeth left at all and the
other had a badly frayed edge.
Needless to say, we replaced them along with the power steering belt.
Brian uses drive belts that are ever so slightly shorter than the originals - although
they are tad harder to fit, it means that the alternator is kept a bit further
away from the right hand exhaust manifold and stays cooler.
On inspecting the brakes, we discovered that they were all in far worse
condition than ever anticipated - although they had met the MOT
standard on the brake tester, you wouldn't have wanted
to use them to stop from 140mph!
All four discs were originals and, being 30 years old,
were more than a little reluctant to come off.
The previous owner had undersealed everything and I mean
 everything.......including the calipers!


Rough front brakes ..........and even rougher rear!
  Not nice!  
But at least the custom-machined halfshafts and their bearings were ok - new set of seals and away we go!


Brian already had a set of brand new discs and calipers for the rear, but the
front was not going to be so simple as although Burton Power had plenty
of the right hand front calipers in stock, there was a
two month wait for the left hand.
Common sense took over my desire to keep 002 totally original and I had
pre-ordered a pair of National Sport vented discs that have the addition
of 8 grooves to help with cooling, together with new Wilwood
PowerLite 4-pot calipers and Wilwood fast road pads.
The Wilwood calipers are a direct replacement for the standard M16 Ford
 items and are actually a piece of cake to install.
Most importantly, they are compatible with the standard 13 inch pepperpot wheels
unlike most other makes, where you need to have 15 inch wheels.


The Wilwood PowerLite 4-pot M16 caliper kit from Burton Power


I concentrated on the after-market front brakes, while Brian was kept
fully occupied at the rear of the car.
Brian is not a fan of altering the original Tickford specification and that was
the subject of much banter, including betting a tenner that
the front brakes wouldn't fit!


I get to grips with the front While Brian deals with the rear
 The Wilwood calipers fitted easily, with just a  Had to make new brake pipes using M10x1 fittings at
 little drilling of the spacer provided in the kit  either end - now I know why they supply the pipe
and substituting a couple of washers  in 5m rolls - it takes that much to get it right!
 By the time Brian had finished, the rear brakes looked like new


Replacing the brake fluid and bleeding the whole system was a bit of a pain
as each Wilwood caliper has four bleed nipples to deal with.
The oil change wasn't much easier as the previous filter had
been fitted by a gorilla!



Well the drive back home to Somerset was pure pleasure.
The journey over to Brian had been taken at a steady 50-60mph,
but you can double that for the way home!
The engine pulls like an express train!
A quick stab of the throttle from idle produces an instant increase in revs
without even the hint of a cough.
Although it is hard to evaluate the brakes this early on with fresh pads
against fresh metal, the initial feeling is that braking
 is much more responsive and positive.


 Ready for the journey back to Somerset


19th August 2012

Time to get the cooling system serviced this weekend.
First job was to drain the system by undoing the bottom radiator hose
where it joins Tickford's bespoke thermostat housing.
The hose is a special size with steel reinforcements running through it
and it's a bit of a pig to remove.
Initially refilled the system with the addition of some Holts Speed Flush
and ran the engine for about 15 minutes.
After the engine had cooled, everything was drained again.
This time, the whole thermostat housing was removed along with the
engine block drain plug that lives just in front of the oil filter
on the right hand side of the engine.
Flushed the radiator and then the engine block.
By the time I had finished, the water was running clear enough to drink!
Thankfully, plenty of water was coming out of the drain plug hole,
indicating that there isn't a build-up of sludge there.


 All the original hoses had seen better days and the thermostat housing needed a good clean-up


Some emery paper soon sorted out the thermostat housing and it was refitted
along with a new 82 degree Motorcraft thermostat and gasket.


I use an old Recaro seat mounted on wheels to get under the car when it is on
 the ramps - can't beat a bit of luxury, plus you can alter the rake of the back
 so that everything is within comfortable reach
The ramps themselves make a pretty handy workbench and storage area too!
There's nothing like a laid-back approach!
Installing the new thermostat
Not forgetting the rubber sealing ring that sits on top of it


Replaced all the hoses with Samco Silicone ones, using a
2.8i kit available from Burton Power.
Rather than the shiny red, black or blue standard hoses, Samco also do
 a "classic black" range that is a closer resemblance
to the original Ford rubber hoses.


The Samco 2.8i hose kit from Burton Power and new Stainless Steel clamps


Tickford originally used the standard 2.8i top radiator hose,
cutting it into two pieces and inserting their
Stainless Steel pipe in between.
No problem doing that to the Samco hose, using the old hoses as a template.
The bottom radiator hose is a different matter however - the standard
2.8i hose supplied in the kit is not suitable as the Tickford radiator
outlet and thermostat housing have a diameter of 43mm,
plus the hose is totally the wrong length and shape.
I have temporarily refitted the old hose, which is not ideal because
 it has started to delaminate and is twenty years old!


Old, but it's still holding water so will do for now


Couldn't resist adding a little more bling in the form of a polished
Stainless Steel expansion tank from Mirage.
Would have kept the original plastic one, but it was looking
quite discoloured and tired.


Looks nice and doesn't deteriorate with heat


Mirage also make a stainless steel windscreen washer reservoir

 that makes an ideal replacement for my melted plastic one.


It this melts, I'll give up!


Finally refilled the system with a 40% mixture of antifreeze and warmed
the car up to check for leaks.
I will  increase the antifreeze mix to 50% after I have drained-down

the system to fit the new bottom radiator hose later.


Engine bay is looking a lot smarter now, but still need to strip the old high-temperature
paint off the turbo and polish the inner wings


Now I have a bit of an embarrassing problem..................
Rust in the bottom left hand corner of the rear window!


A little bit of rust has forced the rear window seal up It looks terrible!


No way is he going to the Haynes show like that, so I have booked
him into our local branch of the Apollo Motor Group to
have the job done.
I have used Apollo before and their work is top-notch.
Build 002 caused quite a stir when I took him down to the bodyshop
for a quote last week and they have kindly agreed to give him a
 thorough machine polish at the same time, ready for the show.
 That will save me some work!
When he comes back from Apollo, it will be a quick rush to get
the interior back in before the show.
 In the meantime, I can get on with completely rebuilding the centre console
while it is out of the car.



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