Jim-GT6

Thanks Josef, my paper copies only go back to June last year. Andy is in my area. We both go the monthly meet. I emailed him and these are his articles. They are very handy: August 2020 https://www.tssc.org.uk/tssc/uploaded_files/482%20August%2020%20Courier.pdf September 2020 https://www.tssc.org.uk/tssc/uploaded_files/483%20September%2020%20Courier%20SEC%20.pdf

Wow. What a project. What a floorpan too. Fabulous. I like the look you've got on the cover panel and that's a great seal. I aspire to something similar .... on an ABS bought one mind you.

Hi Clive, that neat trick will only work if you're in the right place first go. You'd have to keep going bigger from wherever you started. Agree it would be very difficult / next to impossible to start a new location on ABS without a centre drill. It's too hard and skiddy. I don't think so bad on fibreboard though. With patience I imagine you could probably do it using the hole saw by hand, with no centre bit fitted. All the way through, or well enough started to finish with a drill. I'll report back if I try it

Thanks John. That's how I was thinking to try and secure it too. 😂 I was thinking to remove mine! I swear it's why my non-moulded carpets sit so horribly in the footwell. I've currently got a buried footrest under a big pleat of carpet that gets in the way of the clutch! Doesn't fell very sophisticated 😁 Thanks Peter. That sounds ideal. Think I've already got everything needed to copy your tool knocking about. I hadn't thought about extracting the plug without dropping it. Save a lot of swearing!! Last time I did it (which was the first time I'd done it), I was about 2 hours each way! You could get a job in a pit crew Stratton! Seeing all these pictures is super helpful. Now I've got a better idea of where to aim, I'm beginning to think I could try this in situ on my old cover without removing it, enlarge out from a small hole, top up my gearbox, do a fairly crude patch until summer, then rework with a new lined tunnel once the weather warms up. Doug - don't suppose you jotted down those careful measurements by any chance? Prepping one off the car, rather than fixing up the old one, will also make it less of a big single job.

That does look good Doug. Surprised the hole can be that small. Was expecting to need an access hole something more postcard sized. Did the tunnel, seal and lining make a big difference to the heat / noise / fumes? Jim

Hi folks, Old thread I know, but searching for examples of access panels people have cut in their tunnel covers. Anyone got photos? How to make it actually work? How did you choose to fix / seal it? Do you now just peal back the carpet on the side of the tunnel to reveal the cut access panel? My tunnel is original type, and very weak /broken. Held together with gaffer tape at the top front upstand. No good seal. Just old bits of one. Had it out last summer for a clutch slave replacement. I read a good thread (somewhere) on how to strengthen and straighten the old type with glass fibre mesh and resin repair. The author was of the opinion that restoring the original type with this method gave a better outcome than a new plastic or GF replacement. Early summer I plan to remove, repair, modify for access, get a good seal, and hopefully sound / heat insulate. I've seen some of the products - Dodo, Silentcoat etc. What did folk pick? Hoe tick to go? I see the 4mm (thick option) is suggested for tunnel covers. Do folk put heat proof matting on the underside and more sound deadening on the outside? Or just one? I want to dampen the transmission noise primarily, and seal in the cabin a bit. A little heat insulation wouldn't hurt. The many missing grommets and poor tunnel seal don't make for good cabin air. I'd be keen to see photo's of people's mods! The split tunnel idea in the thread above is quite interesting. Would in to need to be cut into 3 parts though to avoid having the take out the H support etc.? If you were to make two cuts from front to back, either side of the mid line, you might be able to create a centre section that stays in place, and good sized side 'wings' that remove?

A second try at video. If no joy ... ho hum High Torque STarter.mp4

Ahh shame. It was a video. I guess videos don't work. I'll see if I can make a tiny one and try again. But, hey, it's 'fyi-fwi-vroom'! that's basically the video 😃

I'm quite keenly ware of my own limitations 🤤 That's why this is so noteworthy. One in a row! 😂

Hi Peter, Sounds like you've got it well sorted for a good deal. I'm not sure I share your friend's worry about the ignition switch. I think it's the same difference, or, swings and roundabouts. As long as when the ignition wire is connected the onboard solenoid you take off the jumper wire, it's the same as the standard setup. Ignition wire to solenoid. Either bulkhead or onboard starter. With the jumper wire and bulkhead solenoid option (as we've both gone for) there is the possibility either one of the two solenoids may fail, and stop things working. So two potential failure points instead of one. I think .... I wanted to keep things simple on the first pass, so opted to leave both active. Easy to switch if the need arises.

Update on the outcome: job done and it went more soothly than I can believe! Delighted. Up on ramps, as I hoped I may stand a chance of getting to the lower starter bolt from below. Knew I may need to remove tunnel cover if not. Once up, took off the cardboard side-valance rear bolts, and pulled the valance away without undoing the front mounts at radiator. As they're flexible, they're easy to manoeuvre. Pulled away with a bend and a waggle. They aren't cardboard I know, but what, fibre board perhaps? Anyway I'm a fan. Was tempted to look at aluminium, but don't expect you can bend and waggle the lovely looking aluminium ones as easily. With the car higher up and the valance out of the way, I could see that I could actually get to both top and bottom fixings from where I was, not even needing to go from below, with a 9/16 stubby spanner on the rear side, and socket on the front. Disconnect the battery. Starter was off in a matter of minutes. Flywheel teeth looked nice and clean and sharp. Old starter not so good. May look inside one day. Needed to know if I needed the spacer(s). Spec. given as a toleranced clearance, rather than mesh. Distance from starter mount surface to closest face of flywheel teeth (distance to flywheel). 18.2mm Distance from starter mount-surface to top edge of pinion (amount it sticks out) - I measured to the very top of the pinion, including the tooth chamfer i.e. the end face of the pinion gear, not the extent of the tooth face width, and ignoring the protruding stub of starter shaft: 23.3mm Spacer thickness: 10.5mm (the actual spacer thickness, which excludes the raised ring, as that mates into the hole) There were also two thin shim plates between the beefy spacer and the mount surface. Flat. Same shape as the beefy one. 0.5mm thick (each) Position without any spacer: pinion would be in 5.1mm interference at rest. With just beefy spacer, in 5.4mm clearance. Haynes states the clearance needs to be 2.4mm to 4.0mm. It was thankfully obvious that I needed the spacer, and that I didn't need the additional two shim spacers, as the clearance is a tad more than required with the beefy spacer alone. I say 'thankfully' obvious, as worst case is to be so much between-two-stalls that neither is gonna work. I'm pretty relaxed about the 1.4mm additional clearance, particularly as the standard starter is referenced to the chamfered face of the fly-wheel, resulting in less contact face width (the old starter pinion has chamfers on it as well, so there are two chamfers reducing the face contact width when the pinion comes in from the back). The new one comes in from the front and there is no chamfer on front face of flywheel, so I've probably got more face-width mesh AND more clearance than the standard starter would allow. The chamfers are each a good couple if mil. I've got one less chamfer. Kept the bulkhead solenoid in circuit, and used the supplied jumper wire between starter main terminal and the on-board solenoid socket (effectively disabling the onboard solenoid I guess). Nuts were tight all the way off, so wire brush and copper slip. Hole in original ring-terminal on the cable was a fraction too small for the new starter post, and a replacement that did fit was in the kit. Had plenty of cable, so cut off the old ring terminal end, plus a bit, to get back to fresh copper, stripped and fitted supplied ring terminal, including heat shrink. Managed with a lighter. I have no power out there. One Father's Day I'll ask for a battery powered heat gun. Vaseline on all the connectors. The cable could so easily end up pressed against the exhaust manifold if not routed to bend the right way, but it's so chunky you can get it to a happy shape and it'll stay. I'd previously rotated the starter mount plate one hole from a first looksee, and that proved worthwhile. The lump is now sat pretty equidistance between chassis and steering column. A good 30mm clearance above and below. Reconnect battery. "fwi-fwi-vroooommmm!". It sounds like a modern, and it sounds way more refined! The three sounds I could expect before were either: "CRANGWAARGARRGGARRRZRAFFERGRAAH!!!!!!!!!!!", or "click ..............", or "berrrrrrrrwumm .........berrrrrrrrrrrwumm ....berrwumm ....berrrrrwumm ....berwum..berwum.. vroooommmm!". I'm going to see if I can upload a video capturing the new audio here. Not sure if I can. Once I knew it was all good, thanks to the experience of Colin and Steve, I put a generous glob of thick silicone sealant over the rubber grommets that are uppermost on the starter. It will bond them in, and seal them far better (they don't feel that tight in there). Maybe it will give me the same 14 years of service as Colin's did, without the water ingress rebuild! Thanks both for the tip. Fingers crossed. I've got some Captain Tolly's sealant too (which I bought thanks to another tip from another Steve at the club) to stop my window seals leaking, but figured that would be a bad idea. It's super-low viscosity as it's designed to find cracks and gaps by capillary. It would likely work its way all inside the starter. Thick jam stuff seals over without penetrating. So .... if you have got a GT6 Mk3, with a standard exhaust manifold, you MIGHT well be able to do this without removing the tunnel cover, or even jacking it up. Get the engine valance out of the way. Stubby 9/16 spanner on the rear, and a couple of socket extension lengths (or another spanner) will do the front side, all from the engine bay. I can't believe how well it went. There is usually SOMETHING that goes bad, or something you come away knowing you've buggered, but not this time. Two hours end-to-end. Well three. Including two tea breaks because I couldn't believe how quickly I'd got to milestones! Copper slip, vaseline, silicone sealant, new crimps and connectors, known clearance that's pretty-well to spec. Would have always worried, if I hadn't measured, that the engagement could be tiny. Just a couple of mm mesh would probably work fine and sound fine at first, but wear the edge of the flywheel teeth and put a lot more radial load on the starter shaft / bearings. Thanks everyone so much! 😃 I mean even the weather was good. Jeeeez. Might go and bet on a horse or something.

I had that when I got the car. Turned out to be a dodgy rear shock and old tyres 😁

Guys you're killing me! 😂 I haven't even taken a spanner to the car yet. I'm likely to need to come back on this topic. At least to give and update on the outcome!

WOSP have a useless website for technical info. I can't confidently identify which of their starters I've got, as the part numbers on the box aren't listed on the website, neither is my car, and all the starters have one common fitting guide to download. Same as the one in the box. No data sheets. Not very impressed. This unit is designed as Pete describes. The leading edges of the gear teeth are chamfered two ways, and the helix is driven in by a spring with a cap on. I think. I read this prevents any clash, but I can't remember where. The faces of the flywheel teeth are flat though, and you could hit them wrong. I guess you might get a single click and need to retry if it needed to tick on one half tooth? It may not need to though, as I could easily imagine the torque applied to the gear through the spring cap as the unit advances and the spring is compress and twisted, could slide it round enough to slip past the leading edge.

😣 I'll allow more time then! Oh well. Another chance to check the gearbox oil.