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