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Thread: Great Beater Challenge Build-1960 Valiant

  1. #61
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    Well got my registration submitted for the 2020 GBC which filled all 75 spots in less than 24 hours!
    Just a little bit popular right now!
    I have been trying to sort the fuel issue I am running into; it wont hold an idle. I did manage to get it running at half throttle and above but it dies like it is running out of fuel.
    Fuel pump checks out and I am running from a jerry can for test and tune purposes so it's not a bad tank or lines.
    Put a vacuum gauge on it and it rapidly fluctuates from 12" to 18" of vacuum so I assume valve clearances are out.
    Pulled the valve cover again (I already ran the valves) and found that the intake valve on cylinder 4 is bent again.
    90064231_10157156016138434_3811744227788849152_o.jpg
    Found out that the intake valve is stuck shut. Dammit-that means pulling the head. Hope it is gummed up from old fuel and sitting for so long and isn't bent.

  2. #62
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    Quite the saga with that engine. I’m on the hunt for my 2020 GBC vehicle and can’t decide if I want to go old or play it safe and get something late 80s-90s.

  3. #63
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    OK I figured out that I had a stuck valve resulting in bent pushrods. The sucky part was how bad were things once I started pulling things apart.
    Ordered a new head gasket for $25 from Rockauto and arrived on my doorstep yesterday.
    Time to dig in I guess.
    Unbolted the manifolds from the head and suspended them so I could leave them in place.

    92704645_10157216564108434_8777720234447470592_o.jpg

    Can easily see the culprit.

    92676378_10157216563778434_1654660425939156992_o.jpg

    The pistons don't look terrible. Will need cleaning but I can see honing marks.

    92516503_10157216563883434_6883873096973942784_o.jpg

    Uh oh what the fu.....

    93111675_10157216563978434_3210888417726431232_o.jpg

    looked at first like a broken chunk of metal. Wouldn't stick to the magnetic pick up-turned out it was a piece of the old valve cover gasket.

  4. #64
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    One quick pass with a wire wheel and things look pretty good.

    92864091_10157216563453434_6904671252766523392_o.jpg

    I will lap all the valves once I hit up a friend for a valve spring clamp so I can remove all the valves.
    And now i got too far into a box of cheap wine with the social distancing G2G with the neighbours so the rest will be done tomorrow I guess.

  5. #65
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    Quote Originally Posted by ianmcc View Post
    This quote is hidden because you are ignoring this member. Show Quote
    And now i got too far into a box of cheap wine with the social distancing G2G with the neighbours so the rest will be done tomorrow I guess.
    5whix.gif
    Quote Originally Posted by Rocket1k78 View Post
    This quote is hidden because you are ignoring this member. Show Quote
    Extraslow nailed it
    Quote Originally Posted by Tik-Tok View Post
    This quote is hidden because you are ignoring this member. Show Quote
    Anyways, think of the Cx5 as the Aspen of cars. Great for middle income families, but terrible overall.

  6. #66
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    Anyone have an empty glass Big Bear or Colt 45 beer bottle?
    Need an overflow bottle and too proud to actually buy them from the liquor store.

  7. #67
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    Well my friend apparently has not seen his valve spring compressor in 10 years and Auto Value isn't loaning tools in the age of covid 19 so I had to improvise.
    Used a length of ¾" conduit and drilled a bunch of holes in it, then used a 24mm wrench to lever the spring so I could fish out the keepers with a pick and a magnetic pick up.
    Attached Images Attached Images

  8. #68
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    No way I was going to hold that while re-assembling them so went the big ass c-clamp route/



    The one stuck valve. Full of crud and rust.



    I cleaned the ports as best as I could along with a little blending then lapped the valves and reassembled everything.
    Might smoke a bit but a lot better than it was.

  9. #69
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    Well as figured with all of the gatherings being cancelled due to Covid19 the news came out that GBC 2020 was also "postponed" until next year with the same rules and route.
    Well we must forge ahead as I want to get this thing roadworthy this summer.
    Got back to putting things back together but found out there was an issue with the rocker assembly.
    https://photos.google.com/photo/AF1Q...83tiVf9JQke0Kv
    There was too much play within the spacers on the rocker arm. Turns out that somewhere in it's past life there are wrong hold downs in between the spacers.
    You can see the difference in width.

    20200419_144941.jpg

    Luckily there was a slant 6 in Bucks that I was able to liberate a few spacers and hold downs.
    So figured it was time to put a third brake light in-but not just anything would do.
    Had one of these Alien Pops counter displays collecting dust in the garage. A little wiring, a spare light, some aluminum tape and black RTV sealant...

    20200418_114921.jpg

    Just set in car for now. I wonder if Johnny Law will hassle me over it.

    20200423_144230.jpg

    So part of this years bonus point structure is for adding cab marker lights.
    Voila! And no drilling-at least until I figure out running the wiring. Probably just run it through the door jam.

    20200423_133737.jpg

  10. #70
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    When we picked up the car and started inventorying the parts that came with the car I noticed a set of motor mounts from a 61 Lancer mixed in with the other items.

    20181201_132546.jpg

    I figured out why as the old ones looked pretty worn.
    Except more than worn once I removed them.

    20200514_135004.jpg

    20200514_134959.jpg

    Swapped them out. The drivers side took two hours-there is a torsion bar mount blocking access to the one bolt on the passengers side. Plus that made it nearly impossible to align all three bolts.
    The drivers side took 10 minutes.

    I always seem to find tools while trolling the local self serve junkyards. My latest find is an 18" Jet crescent wrench; it's a $90 tool on Amazon.
    Beer can for reference (don't eat bananas anymore).

    20200515_152727.jpg

    After I got things all re-attached I can't get the stupid thing to idle-at all.
    It will start and run but at somewhere near 2000 rpm. As soon as I dial back the rpm on the idle screw it immediately dies.
    Have some ideas but that is when I noticed a lot of oil on the passenger side of the motor. It's almost like the oil pump is leaking. After checking it out it looks like the head I just re-installed (with a new Fel-Pro MLS head gasket) is leaking oil.
    Whoops!

    20200606_143521.jpg

  11. #71
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    Whoops!

    20200606_143527.jpg

    There is a void in the block for the pushrods. Unfortunately you can see the block face isn't completely flat.
    (Borrowed this pic from the interweb).

    InkedDSC09447_LI.jpg

    Apparently I bent the gasket placing the head on last time. User error I guess-and I was wrestling that head into place by myself.
    Well I flattened it as best as I could, cleaned the gasket and mating surfaces with carb cleaner and added a coat of red RTV along the thin outer edge then (carefully!) placed the head back in place.
    We will see if that cured the leak.

  12. #72
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    Lots more to add but for now I finally sorted out the no-idle issue.


  13. #73
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    So during the last of many manifold removals necessitated by the head gasket issue I managed to snap off one of the three bolts clamping the manifolds together.
    I am sure no that I had the wrong length of bolt in there as I was cranking down on it due to a leak between them.

    20200612_184955.jpg

    You can see the broken bolt here.

    20200612_184939.jpg

    The fix was a length of 5/16" readi rod cut to length and used as a stud and some red Permatex on the gasket.

    Now not many older cars show up in the local Picky Pulls but there was a Valiant at the 52nd St location. It donated a few pieces to the build.

    20200717_094657.jpg

    Clutch rod, speedo cable and over center spring for under $20.

    20200717_111348.jpg

    So now I have to piece all of this into a working clutch linkage.

    20200717_151940.jpg

    Well most of it anyway.

  14. #74
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    Decided it was time to pull the gas tank and see how much varnish I could drain out and assess the insides.
    Surprisingly it was way better than I first thought. About 2L of old gas but little to no rust inside and aside from the fuel sock literally falling apart in my hands even the sending unit was in amazing shape.

    20200724_123147.jpg

    I cleaned up the rheostat windings and tested the ohms across the range of motion and it looks like it will work.
    I also replaced the deteriorated tar paper covering the tank with some scrap shipping rubber.

    Later that same day we got pummeled with hail down south. The hail damage on the Valiant.

    20200725_150725.jpg

    Just removed some of the oxidized paint. They sure made them different back then.

    Pulled the trans out to work on the linkages and a new gasket (hand cut cork) for the old A903. A super light manual 3-speed with no syncros in first or reverse.
    But not that light if you are on your back trying to bench press it in and out of the bellhousing.

    20200731_143447.jpg

    It's laying on it's back in this pic but you can see the trans mounting pad is slated just like the motor is. The idea was to mount the shifter in the car to the floor and use the existing tunnel.
    This is how the linkage is supposed to go.

    IMG_20171210_144727.jpg

    You can see what looks like an idler for the 2-3 rods.
    I didn't care for that as there was already going to be a ton of slack in the linkages.
    Attached Images Attached Images

  15. #75
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    So I finished off the shifter and linkage I started earlier on in the project.

    20200803_110641.jpg

    The two piece linkage was replaced by a donor caulking gun. Hey this is a super-low budget build!

    20200803_095549.jpg

    So as I feared the linkage was no way no how going to fit under the trans tunnel so I re-worked the shifter and used the existing hole with re-drilled mounting holes.
    Also bent up some ½" conduit for a test fit shifter and mounted up my partners Princess Auto shifter.

    20200820_104556.jpg

    You can see my junkyard-find JC Whitney special gas pedal!
    Installed the over center spring on the pedal hanger and since this year of Valiant was different than literally every other year I had to make a new two-finger c-clip.
    I bent that one out of the remnants of the old shift linkage.

    20200822_140607.jpg

    That is where I ran into a new problem-on most manual clutch linkages there is an adjustable clutch rod with a hole on one end and a threaded adjuster on the other end.
    But I got saddled with a new problem-mine has a slotted fork with a bolt and nut that passes through a different style clutch rod.

    20200824_183215.jpg

  16. #76
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    What I needed was something similar to this...

    s-l1600.jpg

    So I cut and treaded the parts I had to make one up.

    20201011_083040.jpg

    Interesting viewpoint, you say? Well that's because I also decided to try my hand at flux core welding in some floor pan patches.

    Passenger side before...

    20200905_111612.jpg

    During...

    20200905_132711.jpg

    After...

    20200908_055522.jpg

    The donor metal came from my dad's PT Cruiser tailgate we replaced (I never throw out anything).

  17. #77
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    The drivers side in progress. You can see how the shifter is mounted to the floorpan rather than to the trans first then through a hole

    20200908_055544.jpg

    I really hope to get it on the ground and at least driven around the block before the snow really flies.
    And for what it's worth I suck at welding-partially due to sloppy grinding first but I also read online about reversing the polarity on flux core welders so the power runs through the ground clamp first then up the wire.
    Since it's my partners welder and he hasn't taken it out of the box since buying it I figured it's time to hack the welder.
    It's a cheap Mastercraft welder so it wasn't as easy as unbolting the lugs and flipping them around.
    Let's just say that I have a fire extinguisher and I didn't need it and my first test welds with the new and improved welder worked out seem much better.
    Last edited by ianmcc; 10-11-2020 at 08:47 AM.

  18. #78
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    Cool build thread. I have a 67 Barracuda fastback 273 sitting in my moms garage i've been wanting to do. No garage space currently, but i'm gonna do it when i move and get 2 garages
    Machining, Fabricating, Welding etc.

  19. #79
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    With the nice weather I should be burning shit together with fire but instead I came across a complete roof rack on an old M body wagon at Bucks.
    A little slice and dice and re-assembly and a test fit for length and width. Thank goodness there is no headliner so I can bolt it in easier. Was trying to avoid drilling the roof if I could.

    123037980_10157750330638434_8201601921189402115_o.jpg

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