PREPARING THE ENGINE FOR START-UP

During a restoration it is all about the details when it comes to starting an automobile engine for the first time.  So many factors can prevent the engine from running properly or for that matter, at all.  Failure to double check every connection can cause serious damage to a new engine.  Again, it is all about the details.

When I ordered the wiring harness, I didn't realize that the overdrive wiring was not included.  The harness shown at the top of the photo the right is the new overdrive wiring.

I also connected the oil filter today.  It was not an easy task.  I actually had to remove the filter bracket in order to assemble the system.  Spin-on filter adapters are available, but we must go with the original.  

I also wired the distributor and coil today.  The plug wires and coil wire on the original distributor cap were attached by set screws that penetrated the wires, thus making the connection.  A bit more difficult than current technology, but again, it is original.

PREPARING FOR UPHOLSTERY

My crew was on holiday today, so I worked in the shop alone.  I spent about half a day putting the finishing touches on the seat frames.  A small wooded strip is fixed to the bottom of the seat back on the bucket seats.  It is used to fasten the upholstery material to the metal frame.  One of them was missing.  I fabricated the tack strip and fastened it to the seat back.  

I also applied the finish coats of paint to the rear seat pans.  I used a semi-gloss black urethane paint to duplicate the original.  The bottoms of the seat pans are visible from underneath the car so it is imperative the the coating duplicates the original.
There are several upholstered panels on the Healey that have a plywood backing.  At this point, I do not know if this backing is included in the upholstery kit.  The kit should arrive sometime this week and we will begin the upholstery process, whatever it requires.

Sorry, no pictures today.

Tom McCurry

RESTORING THE SEATS

The upholstery on this Healey was a bit dated.  I suppose it had been replaced back in the 70's when metallics were used in automobiles ad nauseam.  

We removed the upholstery material and padding to find the seat frames to be in exceptional condition.  There was only light surface rust.  

The rear seat pans were a bit more rusty but not compromised.  A bit of sandblasting and self-etching primer took care of the problem.

All the seat frames have been refinished now and are awaiting the new leather.  It should be received sometime this week.

The archive listing of this blog contains detailed step-by-step photos and narratives regarding this restoration since it began late last December.  Please direct comments and questions to tommystoplesscars@yahoo.com.

Y'all come back now...

Tom McCurry

THE BODY WORK

We spent the week completing the body work on the door, rear fenders and boot lid.  With all the panels in primer and ready to be "blocked", we assembled those body panels to the chassis.  They fit very well.

 We fitted the panels to make sure the margins between the doors, fenders and rockers were consistent and adequate.  We also wanted to check the alignment of the body line between the doors and fenders, because the area below the line will be painted Old English White.

Blocking will begin on Monday...Colorado Red by the end of the week.

Stay tuned...

Tom McCurry

ENGINE BAY WIRING COMPLETE

Thanks to a factory wiring diagram, an abundance of pictures of the Healey before it was dismantled, keeping the original harness intact and a basic knowledge of automobile wiring, the engine bay wiring is now complete.
The photo to the right shows the installation of the fuse block and the overdrive switches.

Shown in the photo to the left is the voltage regulator.  The flasher relay is pictured below.  All the electrical components are reconditioned original equipment.

The archive listing of this blog contains detailed step-by-step photos and narratives regarding this restoration since it began late last December.  Please direct all comments and questions to tommystoplesscars@yahoo.com.

Stay tuned...

Tom McCurry

THE WIRING HAS BEGUN

Fortunately we had labeled the original wiring harness as it was being removed.  Today we laid out the new wiring harness on the floor beside the original one.  At that point it was easy to see how the harness is positioned in the car.

The photo above shows the new harness properly routed in the engine compartment.  There are a million connections to be made, but the wiring is well underway.
The archive listing of this blog contains detailed step-by-step photos and narratives regarding this restoration since it began late last December.  Please direct comments and questions to tommystoplesscars@yahoo.com.

Wish you were here Tim...

Tom McCurry

THE CARBURETORS ARE INSTALLED

We had fitted the carburetors to the intake manifold last week.  Today, we connected the reconditioned original air cleaners and breather tube.  

The engine's fuel delivery system is now complete.  After the fuel tank has been sealed inside and connected to the fuel pump, the system will be ready to test.

The archive listing of this blog contains detailed step-by-step photos and narratives regarding this restoration since it began late last December.  Please direct comments and questions to tommystoplesscars@yahoo.com.

One step closer...

Tom McCurry

THE COOLING SYSTEM IS COMPLETE

We installed the radiator and connecting hoses to the block last week.  The heater connections were completed today.  

The copper pipe shown in the photo to the right connects the discharge side of the water pump to the heater coil.  Another hose connects the discharge side of the heater coil to the block, thus, recirculating the heated water in the engine.

The heater hose connections to the coil are shown in the photo to the left.  The original style wire hose clamps were used throughout the system.

The cooling and heating systems are now complete.

The archive listing of this blog contains detailed step-by-step photos and narratives regarding this restoration since it began late last December.  Please direct comments and questions to tommystoplesscars@yahoo.com.

Back soon...

Tom McCurry

INSTALLING THE HEATER BLOWER DUCTS

The heating system picks up fresh air from the front of the car.  The air moves through the blower motor, which is mounted on the right front wheel house, to the heater coil located under the dash and is distributed on both sides of the car under the dash.  

The new hoses, which are readily available from Moss Motors (mossmotors.com), are connected to the heater box and blower with the correct wire hose clamps.

There is also a fresh air hose located on the driver's side of the car.  This line is not routed through the heater coil, so the air temperature is almost the same as the temperature outside.  It can be opened and closed at will.  This system is far from air conditioning, but it is better than nothing.

The archive listing of this blog contains detailed step-by-step photos and narratives regarding this restoration since it began late last December.  Please direct comments and questions to tommystoplesscars@yahoo.com.

More tomorrow...

Tom McCurry

DETAILING THE VALVE COVER

This valve cover has many small parts.  The badges are sold separately and are riveted in place.  The crankcase breather tubes are connected to a manifold in the top of the valve cover and the oil filler cap is connected to the valve cover by a small wire rope.  All in all, it's a bit time consuming, but the end result is almost a work of art.

There are two fasteners that attach the valve cover.  Rubber grommets seal the holes in the valve cover to prevent oil leaks.














Today, I also repainted the cooling fan yellow to its original  specifications.  The fan guard, will be repainted red...colorful isn't it.














Love this Healey,
Tom McCurry

CONNECTING THE VACUUM ADVANCE

The distributor is equipped with a vacuum advance which advances the timing as the engine accelerates.  The distributor uses the vacuum created by the intake manifold.  The two are connected by a small piece of steel tubing.

If you look closely in the photo to the right you will see the vacuum line connected to the distributor.

I also connected both the top and bottom radiator hoses.  Notice, in the photo to the left, the use of the original style wire hose clamps.

Having fun!

Tom McCurry

Please direct questions and comments to tommystoplesscars@yahoo.com

INSTALLING THE FRONT SWAY BAR

The front sway bar connects the frame to the lower spring pan, thus, stabilizing the front suspension.  The frame and spring pan connectors were replaced.  New urethane bushings were also installed.

Notice how the spring pan and sway bar are "sandwiched" between the new bushings.  The frame connection is isolated by a red urethane bushing.

New, new, new...

Tom McCurry

Please direct questions and comments to tommystoplesscars@yahoo.com

THE COOLING SYSTEM

We experienced another productive day.  Don began dismantling the bucket seats while I assembled the cooling system.  

After refinishing the blades, I installed the fan.  Notice the four blades are not diametrically opposed. Another engineering breakthrough I suppose.  

Next, the radiator was bolted in place.  Tim had purchased a new one rather than restoring the original.  It was in questionable condition.

You will also notice the horns are now in place.  The were cleaned, primed and re-painted their original color.  Tomorrow, the radiator hoses will be connected.

Stay tuned...

Tom McCurry

Please direct questions and comments to tommystoplesscars@yahoo.com

WHAT'S NEXT ?

Now that the power plant is in place, we are focused on installing all the peripheral equipment.  We are making an effort to getting this car running in a week or so.  

I began the day by attaching the generator.  The bracket shown on top of the generator is for the coil.

The black canister shown in the photo to the left is the reservoir for the hydraulic brake and clutch systems.  Notice the label.  It is the correct decal for the reservoir. 

After the slave cylinder that operates the clutch is connected, both systems are ready to be "bled".   At that point, we can stop the car but we still can't make it go.

Life is good,

Big Healeys are BAD !

Tom McCurry

ENGINE AND TRANSMISSION INSTALLED

This has been the perfect day.  I have never had so many things go right on a Monday especially when an English sports car is involved.  By noon we had installed the engine and transmission.  It isn't always that easy, but certainly note worthy when the process goes smoothly.

The photo to the right shows the engine and transmission attached to the hydraulic hoist and the Healey prepared for the installation.

In a matter of only a few hours, power plant was bolted in place.  The best part...only one small scratch.  You will notice, in the top center of the photo to the left, we used a  device that allowed  us to tilt the engine 45 degrees.  This made it much easier to maneuver the engine to its proper location.

The transmission is attached to the frame by the rear mounts.  There is also a tie-rod connecting the transmission to the frame.  It cannot be installed until the car is once again lifted off the floor.

Now the engine and transmission is properly fitted to the car.  The carburetors, linkage and fuel lines have also been connected.














Tomorrow, the installation of the generator  and engine wiring will be completed.

It's coming together...
Tom McCurry

Please direct questions and comments to tommystoplesscars@yahoo.com

ANOTHER BEFORE AND AFTER

I enjoy posting the before and after photos.  It's a reminder of what neglect can do to an automobile and a testimony to hard work.  Shown in the photo to the right is the engine compartment after the engine and transmission was removed.

After many hours of sandblasting, cleaning, painting and refitting, we have a "new" engine compartment.  Yes, it is the same Healey.

Stay tuned...

Tom McCurry

MOUNTING THE FUEL TANK

The fuel tank and the interior of the trunk, or boot, have been finished with urethane paint.  The fuel tank was in excellent condition.  Evidently the fuel had been drained when it was put in storage...a very good thing.  Gasoline tends to "varnish" after a period of time and will cause problems with fuel pumps and carburetors.  If you need to store your vehicle for an extended period of time it is best to completely remove fuel from  the fuel tank, pump and carburetors.

 After the trunk space was painted, the foam seal was applied to the opening in the floor.  The fuel tank drain is exposed to the underside of the car through this opening.  You will also notice the new battery cable on the right side of the photo that has been routed from the front of the car. 

The fuel tank will be mounted on Tuesday.  Monday, we will have a busy day installing the engine and transmission.  We are prepared.

Love this Healey...

Tom McCurry

ARE YOU SITTING DOWN...

Although it was another hot day in Hilton Head, we accomplished a great deal of work.  This morning, we installed the new battery cable.  It is clamped to the frame just below the brake line and routed to the battery location in the trunk or "boot".

We installed several of the electrical components as well as the body tags to complete the preparation of the engine compartment to receive the engine.  The heat shields are in place as well.  

Now, for the moment you have all been waiting for.  We fitted the wheels to the axles, lowered the Healey to the floor and removed the rotisserie.  

It's beginning to look like a classic Healey again.  The Healey appears to be so low and sleek now that it is on the floor.  I suppose that is because we have been working on it at eye level for several months.

Tomorrow, I will be installing the fuel tank and straps.  All the components have been refinished so the installation should not be time consuming.  

On Monday morning, we plan to install the engine and transmission.  The body work and paint work on the fenders and doors continues.  

I remain excited...

Tom McCurry

INSTALLED FACTORY HEAT SHIELDS AND PEDALS

Although it was over 100 degrees in the shop today, we managed to put in a full day of work on the Healey.  Tim had purchased a complete set of factory reproduction heat shields for the engine compartment.  

You can see in the photo to the right that the panels do not fit perfectly, but neither did the originals.  The reproductions are an exact copy of the originals.

We also managed to finish the installation of the brake and clutch pedals.  We virtually destroyed the connecting shaft and bushings when we dismantled the assembly but the parts were readily available.  At any rate the assembly is now operable and the system is ready to "bleed"

After we install the battery cable, the starter solenoid and the wiring harness, we will be ready to put this Big Healey on its "feet".  This will happen on Friday.  Can't wait...can you?

By the way, I have installed a link to my email address in the upper right hand corner of this blog page. I invite your questions or comments.

Life is good,

Big Healeys are BAD.

Tom McCurry

WHEEL ALIGNMENT

Before we drop the Healey on its "feet", we completed a "rough" alignment.  With the wheels off the ground, the alignment process is much easier.  We set the "toe" simply by measuring the front and rear of the wire wheels.  

Now the front suspension and braking system is complete.  With the rear suspension also complete, we are prepared to mount the wheels.  We will use the original ones only to make the final cleaning process easier.

I have installed a "contact us" link on the page.  We invite your questions and comments.

Looking good...

Tom McCurry

FITTING THE WINDSHIELD WIPER MOTOR

The wiper motor was in excellent condition and required only cleaning and new fasteners.  The installation was uneventful...for a change.

The wiper motor fits behind the dash.  It is truly a shame to hide it.

Love this Healey...

Tom McCurry

INSTALLING THE HEATER/DEFROSTER ASSEMBLY

After completely reconditioning the heater, including replacing the heater core, we fastened it into place today.  All new fasteners were used because the originals were rusted and were destroyed during the removal process.  The corrugated hoses connect the heater box to the defroster vents.

The screws shown in the lower left quadrant of the photo above connect the heater box to the ductwork that extends the width of the car.  The polished stainless steel vents, shown in the photo to the left,  fit underneath that duct.  There is one vent for each side...not a great deal of air flow.

Stay tuned...

Tom McCurry

INSTALLING FRONT BRAKE CALIPERS

After rebuilding the front disc brake calipers, we mounted them on the swivel axles.  The new brake lines were fabricated and attached to the flex lines and calipers, shown in the photo to the right.

Now the suspensions, front and back are complete.  Next the wheels will be attached. We are all looking forward to seeing this car on its wheels.

The clutch and brake master cylinders are now permanently installed and the hydraulic lines attached.  

Life is good,

Big Healeys are BAD...

Tom McCurry

INSTALLATION OF ACCELERATOR LINKAGE

This is a very complicated accelerator linkage.  On later cars, all this linkage was replaced by a bicycle cable from the accelerator pedal to the carburetor and a short linkage connecting the two carburetors.  This has "engineering overkill" written all over it.

The photo to the right shows the accelerator pedal after it has been refinished and installed

In the top right section of the photo to the left you will see the connection of the accelerator pedal to the relay shaft.  The relay shaft is shown in the center of the photo and is hung from the underside of the firewall.  I suppose it was designed in this fashion to easily adapt to right hand and left hand drive cars.

The linkage is connected to the engine by means of the throttle relay shaft, pictured to the right, secured by a rubber grommet in the firewall.  When the engine is installed the nylon pillow block on the opposing end of this shaft is connected to the intake manifold.  This system is actually pretty cool.  A bit complicated, but cool.








I plan to work tomorrow installing the front brake calipers.  This will complete the installation of the front suspension.  We will be fitting the wheels next week in preparation of installing the engine and transmission.
Stay tuned, this car is really going to change in the next couple of weeks.

Tom McCurry