The story of our Red T2, Jiggly (Project thread)

[Lazy-Ferret]

So, after having my Tonka T2 Fuzzmobil for 3 years or so, and not being able to get old the T1 back on the road, Suz decided she wanted her own road worthy one.

After looking around for many months, a member on here posted up they were selling a 2000 red one. Suz has always liked the Red over Silver, and after looking at it, she bought it.

I knew there were a few jobs to do, when I bought it, like an Aircon leak, and the sunroof motor, Centre console armrest clip, radio, plus Suz wants lots of lights as well.

Why Jiggly? Well the last 3 letters of the Registration are JGY, and that was the first thing that came to mind.

We got the car home on the Wednesday night, and and barely had a chance to look at it, as we were going away on holiday on the Saturday, so Jiggly was parked up at the edge of the drive, between her predecessor, and My Tonka Toy.

 

[Banshee]

So, after having my Tonka T2 Fuzzmobil for 3 years or so, and not being able to get old the T1 back on the road, Suz decided she wanted her own road worthy one.

After looking around for many months, a member on here posted up they were selling a 2000 red one. Suz has always liked the Red over Silver, and after looking at it, she bought it.

I knew there were a few jobs to do, when I bought it, like an Aircon leak, and the sunroof motor, Centre console armrest clip, radio, plus Suz wants lots of lights as well.

Why Jiggly? Well the last 3 letters of the Registration are JGY, and that was the first thing that came to mind.

We got the car home on the Wednesday night, and and barely had a chance to look at it, as we were going away on holiday on the Saturday, so Jiggly was parked up at the edge of the drive, between her predecessor, and My Tonka Toy.

Nice line up there buddy :thumb2

 

[Lazy-Ferret]

Unfortunately, as we set off on Holiday, towing the caravan, my Fuzzmobil must have seen the new car as competition, and promptly threw her toys out of the pram, blowing her radiator up on the M25. After being recovered back home, we decided to steal the radiator out of Jiggly, and see if my Fuzzmobil had managed to survive the breakdown. Good news was, no permanent damage to my car, so we were able to get away on Holiday.

Once back home, it was time to sort Jiggly out.

When I took the cooling radiator out, I noticed the florescent green dye from the aircon fluid all over an area of the aircon radiator, so knew we would now need to replace both.

When I removed the radiator, I also noticed the water level in Jiggly was low, and upon further inspection, found signs of a leak from the cast thermostat housing under the top hose.

So, after sourcing replacement radiators (Thanks Rick), I set to work.

I went to remove the thermostat housing, and the two long bolts sheered. Weirdly, the other one, was like new... As this housing is bolted down and across, it is effectively still fixed in place by the sheered bits of the bolts. Oh, and to make things harder, there are 2 bolts hidden under the overhang, not just the one shown in the workshop manual!!!

After a lot of drilling and levering, I got the housing off, and then set to work removing all the sheered bolt remains and gaskets. I then spotted that in my over eagerness with the levering, I had cracked the housing underneath.

So, as I was now in need of more bits, I decided to wash up, and do a bit of searching on the computer for parts.

On second thoughts, as there was still some daylight left, I thought I would go out and have a go at the sunroof motor...

First problem, the motor bolts will not undo. The plastic moulding with the captive nuts had disintegrated. I eventually got the motor out, well after dark, and brought it in to have a look at.

Once I opened it up, it was literally full of a brown sticky powder. I cleaned it out, and looked at the switches, which do seem to be overly complicated, 2 micro switches and a solenoid... The solenoid was rusted up. After a a couple of hours of careful cleaning, and lubricating, and more cleaning... I got it all working.. 1st success of the day...

Time for Bed....

So list of Jobs now, with the ones I have added, and others I have subsequently found.

New plastic captive nut section for the Sunroof
Refit roof motor
add usb charging module to map lights for dashcam
New Thermostat housing casting
New Thermostat
Keep eye for ally thermostat cap, as this has a plastic one.
New Aircon radiator
New Cooling radiator
Centre Console clip, Have tightened screws which has reduced rattle)
New/repair steering wheel, as stitching has come apart
Put on bullbars
put modified led lightbar on bull bars
add wires for second battery, and extras.
add second battery
and more to add...

 

[Lazy-Ferret]

Back working on Jiggly today.

Yesterday, I ground out and cleaned up the damaged part of the aluminium thermostat housing, and repaired it with Liquid Steel. Luckily, I could get to both sides, so fingers crossed, it should be good.

Also yesterday morning, I ordered a new Aircon radiator/condenser, but was offered 2 sizes. I went and measured mine, and gave them the measurements, and had a result, as my size was the cheaper unit. I picked it up in the evening, and upon opening it, realised the connections were different. Mine has two pipes, this one had one pipe, and a connection block.

Today, I learnt that radiators are measured by the core size, not the overall size, so I returned the wrong unit, and hope to have the replacement correct, more expensive one tomorrow.

The good news, the bolts I ordered to replace the ones that sheared off, on the thermostat housing, arrived this morning, so I set to work refitting that. I used liquid gasket, as sourcing replacement genuine ones was very difficult. While I had it all apart, I changed the thermostat for an 88degree one.

I then set to work removing the old Aircon rad... that turned into an epic. I searched several places on the web, and got a couple of different ideas on how to do it. They are very wrong.

First one I found, said to remove grill, remove left Head light, remove condenser, refit in reverse order... first problem with those instructions is, to remove the headlights, you have to remove the bumper cover!!!

After making a post on here, and being told you have to remove the bumper, I set to work doing it the long way. I did consider removing the bar that runs down the middle of the grill, with the bonnet catch on, but this would mean drilling out the spot welds, and I could not bring myself to do this. Ironically, checking the forum later in the evening, this was exactly what another member has done....

Second problem, all 4 of the Pozidrive bolts in the wheel arches that hold the bumper cover on, were seized solid, and rounded off in no time, so I had to set to work removing them... I had (Past tense) a box with various sizes of screw removers in, so thought I would try them out... I managed to snap two in the screw heads, meaning I could not now drill them out!!! Handy. So, I ground the heads of the bolts...

Third problem, all 8, well 5, as 3 were missing, of the plastic trim clips shattered into a million bits as I tried to remove them.

Forth problem, the wing location where the bumper cover slides on, is completely rotted away, so there is just a big hole there....

Finally got the condenser out. I now have florescent green hands, from the leak detection dye that dribbled out. As the condenser comes out the front, I decided to re-fit the cooling radiator, and make sure there were no leaks there. So I fitted the radiator I got from Rick, and filled the system up with just fresh water for now to check it out. I will drain it all back down and put in the proper coolant, once I know it is all OK.

Started the car up, and noticed the MIL light was on... What now?

Made up a momentary switch on flying leads, to test the codes, and found it was the water sensor. It must have been unhappy when I was turning the ignition on and off the other night, while removing and testing the sunroof motor. I did that after I had removed and disconnected the thermostat housing.

Ended the day on a High, as I cleared the MIL, and it did not come back on, not only that, but let car come up to temp, and can not see any water leaks...

So list of Jobs now,

Order plastic trim clips, and bumper screws
Look into probably replacing front wing
New plastic captive nut section for the Sunroof
Refit roof motor
add usb charging module to map lights for dashcam
Keep eye for ally thermostat cap, as this has a plastic one.
New Aircon radiator
Centre Console lid clip, have tightened screws which has reduced rattle
New/repair steering wheel, as stitching has come apart
Put on bullbars
put modified led lightbar on bull bars
add wires for second battery, and extras.
add second battery

 

[terranosaurusdoug]

I only have to look at those bloody pozi-screws and they snap
I've been trying different penetrating stuff, I even made my own using acetone and ATF fluid, but noooope, not having it!

Keep it coming matey, I feel less alone in my struggles now :lol :thumbs

 

[emjaybee]

Aah, just another day in paradise.

:doh

 

[Lazy-Ferret]

Well, the bad news was, when I re-checked the cooling system, there was a lack of water... I re-filled it, and then pressure tested it, only to see water spurting out of the rear of the radiator, right in the centre, about a third of the way up... So I added a cooling radiator to the condenser order....

Got the two radiators, so today I thought I would crack on with getting them in, before the really bad weather gets here...

I started the day removing the leaking radiator.
Fitted the new aircon condenser, and connected it all up. Will have to get it re-gassed now.
Fitted the new cooling radiator, cowlings etc, and refilled it all. This time I pressure tested it, and it maintained the pressure while I had lunch..
Drained it all again, then refilled it with 4.5litres of antifreeze... I could not get that last 1/2 litre in.... But close enough. Re-tested and all seems ok.
Remembered to re-fit the engine tray, this is a pressed steel one, and quite heavy, need to look out for one of those for the Fuzzmobil, as it does not have one at all.
Refitted o/s head light
Refitted Bumper.
Refitted sunroof motor, still works!!

Result, the car is now back on the road... Time to start mod'ing...:naughty

So list of Jobs now,

Look into probably replacing front wing
New plastic captive nut section for the Sunroof
add usb charging module to map lights for dashcam
Keep eye for ally thermostat cap, as this has a plastic one.
Centre Console lid clip, have tightened screws which has reduced rattle
New/repair steering wheel, as stitching has come apart
find and put on bullbars
put modified led lightbar on bull bars
add wires for second battery, and extras.
add second battery

 

[Tate]

Nice job. Hope that I will get that far with my project that I could start modding it.. :doh

What do you mean with bad weather? Do you have snow there during winter time?

 

[harlowmaverick]

I like this story, looks like a happy ending is in sight!!

 

[macabethiel]

Do I detect age related listing syndrome ?

Interesting thread reminded me of my younger days when I did most of my own repairs.

Interesting to see you doing job listing on the post hope you go the full monty at home and tick off as you go with beer rewards! lol

 

[Lazy-Ferret]

Thanks guys. I thought that as Suz won't let me mod this one to the extent mine is, it would make an interesting trials and tribulations of running a second hand car.

Nice job. Hope that I will get that far with my project that I could start modding it.. :doh

What do you mean with bad weather? Do you have snow there during winter time?

We do get snow in Kent, and it tends to be a case of local heavy areas, with nothing in other places, but not normally this early in the winter, we are on standby for local flooding this week/weekend, so possibly some 4x4 response work though. They say the temp is going to drop significantly though over the weekend, and while I will work on the car in the odd shower, and prefer cooler weather for working on cars, when it gets too cold you seem to do a lot more damage to yourself, which results in pain, and I draw the line there unless it is an emergency.

Sent from my SM-T705 using Tapatalk

 

[Lazy-Ferret]

Well, made some progress today...

Fitted Bull bars...

Just need to finish the modified light bar now to go on it.

Then fitted the USB module to the over head map lights, so the Dashcam has an ignition controlled feed.

The module

All fitted

list of Jobs now,

Look into probably replacing front wing
New plastic captive nut section for the Sunroof
Keep eye for ally thermostat cap, as this has a plastic one.
Centre Console lid clip, have tightened screws which has reduced rattle
New/repair steering wheel, as stitching has come apart
put modified led lightbar on bull bars
add wires for second battery, and extras.
add second battery

 

[emjaybee]

Nice work!

Two questions,

1. Love the bull bar, where did you get it?

2. Love the USB better than your last one, where did you get that?

:thumb2

 

[Lazy-Ferret]

Nice work!

Two questions,

1. Love the bull bar, where did you get it?

2. Love the USB better than your last one, where did you get that?

:thumb2

The Bull bar was already on the T1, when we got it. I had to make up some plates, to get it to fit the T2, but very pleased with it.

I am puzzled, "my last one"? I don;t remember posting anything about the one in the Fuzzmobil.
I got the module off Ebay, finding one with a Mini connector limited my choice, but that one does the job perfectly.



Took the car out for a nice long run today, and found some extra bits to add to the "ToDo" list...

The Passenger, and rear O/S windows do not work.
Terrible wheel balance problem at 50mph
Tracking out as well, Suz had it screaming like a banshee going round the M25 J9 roundabout.

list of Jobs now,

The Passenger, and rear O/S windows do not work.
Wheel need balancing
Tracking out
Gas Air Con
Look into replacing front wing
replace plastic captive nut section for the Sunroof
Keep eye for ally thermostat cap, as this has a plastic one.
Centre Console lid inner moulding
New/repair steering wheel, as stitching has come apart
put modified led lightbar on bull bars
add wires for second battery, and extras.
add second battery
Make second Flip key.

 

[jims-terrano]

Yeah like the usb cable, have you got an ebay link.

Cheers

 

[emjaybee]

Sorry bloke, I must be getting confused. I thought it was you who built a USB port into the map-light pod.



Really like the nudge bar though.

:thumbs

 

[Lazy-Ferret]

Yeah like the usb cable, have you got an ebay link.

Cheers

http://www.ebay.co.uk/itm/221547097296?_trksid=p2060353.m2749.l2649&ssPageName=STRK%3AMEBIDX%3AIT

It took just under 2 weeks to get here, but worth the wait, as nice and small. A bit of double sided tape holds it in place.

 

[Lazy-Ferret]

Been a bit busy, so only a couple of bits done to the car this weekend.

Finished the flip key, had to change the switches on the remote, as they were not very good to start with, and became very flaky once I changed it into the flip case. Now it is all good, just got to do the other one now.

Job for the weekend was to run wires for the accessories I will be fitting.

Before I get to a point of connecting everything up, I will probably need to change the Positive battery terminal. I had noticed in the past, a thick 40 amp cable running from the positive terminal, and a thin 5amp(ish) cable running from the negative, taped to the pipes running across the back of the engine bay, before disappearing through the bulk head. I presumed the thick wire is the tow bar feed, but no idea what the thin earth could be. So first job of the day was to look and see exactly where the positive cable was connected on the battery terminal as it was not immediately obvious, coming up from underneath. As I put my hand on the wire, it just came away as there was only about 10 of the 30 or so strands in the crimp, and they had all but a couple snapped away.

Not a problem, as the main job was to run a nice thick 165amp feed cable, and a 12 core signal wire from the engine bay to the boot. This entailed taking the passenger seat out, and all the trim along the N/S, so I could get to the cable trunking under the mat, and run it neatly and safely to the back. The orriganal two wires from the engine bay were just run under the trim panels, and were pinched in several places, with the thin one flat most of the way along, with the copper showing in a few place... to be honest, it almost looked melted...

When I removed the N/S boot panel, I got my first glimpse of the wiring for the towbar... Oh dear.... Everything was blue scotch locked, which is horrible, but unfortunately common practice when people fit towbars.

I was intrigued though, about the earth wire, as I had followed it all along the length of the car, and found it terminating in a mass of Blue Scotch locks. As I worked it out, I nearly had heart failure... Basically, the 13pin towing socket, has 3 large earth wires, 1 for all the lights, one for the fridge, and one for the continuous 12v feed. These wires are all quite thick, rated at about 25amp (ish) each, and way too big for a blue scotch lock to be used safely. But there before me was the lighting earth connected to the fridge earth, then the fridge earth connected to the permanent 12v earth, that connected to a flying bit of wire that came from the split charge relay, and then all of them, connected to the thin earth wire running from the battery.... Basically, the whole caravan towbar socket was earthed via the small wire, all the way back to the battery at the front. How it never caught fire......

I am so glad I did not just chuck the caravan onto the back of the car, when my car killed it's radiator the other week, and use it instead of mine to get away on holiday. Lesson here is never trust a towbar wiring if you do not know who fitted it.

Anyway, I finished getting my wires to the boot, removing the old wires as I went. I then set to work, running another 12 core cable from where I will be putting the control panel, near the centre console to the engine bay. To do this, I removed the glove box, and central dash.

While I had the glove box out, I decided to check the pollen filter....

I think it may need changing...

Ran out of time and daylight, so while I have the centre dash out, I am going to make up a panel for putting an after market radio in, and remove the ashtray, and make a panel for some extra switches there.

list of Jobs now,

Change pollen filter
The Passenger, and rear O/S windows do not work.
Wheel need balancing
Tracking out
Gas Air Con
Look into replacing front wing
replace plastic captive nut section for the Sunroof
Keep eye for ally thermostat cap, as this has a plastic one.
Centre Console lid inner moulding
Boot door carpet Trim panel broken along edge
New/repair steering wheel, as stitching has come apart
put modified led lightbar on bull bars
add wires for second battery, and extras.
add second battery
Make second Flip key.

 

[terranosaurusdoug]

Wow, I bet that filter is the original one, I will check mine after seeing that!!

 

[Banshee]

Wow, I bet that filter is the original one, I will check mine after seeing that!!

Yeah me too, mine should be about due I reckon, should improve air flow as well to get that heat round the car for those cold winters mornings :clap