Welcome
It took 2.5 years to build the car and pass SVA (now IVA) and a lot longer to get to where it is now! To see the Sportster out on...
Throttle Body Vacuum Leak, New Bearings
Bought a leak tester recently. The DIY version I had been using is jank, this is plug and play - works really well. As an initial test I check the...
Camber and Caster Adjustment
I've had some questions how how the camber and caster are adjusted on the Sportster. The following images are not dimensionally accurate, they represent the adjustments available. The Sportster has...
Timing / Cam Belt change
It’s been too long since changing the cam/timing belt on the M20. It's nowhere near the mileage limit but it's far too many years overdue. I ordered a new Contitech...
Noise suppressor for intercom
The intercom had a noticeably irritating alternator whine after installing and testing, pitch increased with RPM. There's an official noise suppressor from Rugged but is $40 before shipping, import duty...
Intercom
The Sportster is great for short trips and hooning little, but it isn't quiet and on longer journeys that can be fatiguing. You also mostly can't hear the head unit...
Fuel filters and one way valve
The fuel filter elements are the originals from 2005, so it was time to change them. The good thing Sytec still make the bullet filters and the elements are available...
Wiper Motor Smoked
Took a test drive after swapping the shock top mounts. It's a few days until MOT time and this is obviously when things like to break. I had no wipers,...
Shock Refurb Part 2
The ball joints in the gaz shocks were worn out, they didn't have an upgrade unit available with stock BMW top mount/shock positioning. I therefore looked for an alternative which...
Shock Refurb Part 1
Last year the MOT person mentioned there was excessive movement in the rear shock mounts. After some testing it was mainly the top mounts. They are from Gaz Shocks, purchased...
Clutch Hosed
Sometimes you shouldn’t touch a thing, but in this case it was a good thing. Sportster clutch pipe from the reservoir to the master had a split so it leaked...
Differential Bushes
The differential has been sqeaking and nods up and down under load so it was time to get some new bushes. Both sets of bushes are from https://www.powerflex.co.uk/ - the...
Engine and Gearbox mounting bushes
Recently the alternator hit the chassis when I changed direction, a good indication that the engine and gearbox mounts might need some attention. Unfortunately the alternator bearings were damaged due...
High level brake lights and indicators
Installed a 3rd level brake light 9 years back as a 'temporary' solution to make it clearer when I was using the brakes. I've been meaning to install something cleaner...
Reverse a switch – upated brake fuild level warning circuit
On a 1988 car the brake level sensor works the opposite way around to a 2011. On the 1988 when the brake level gets low the switch connects the circuit...
Brake Fluid Reservoir / Expansion Tank
Recently tried to flush the brake fluid with a pressure bleeder. It uses a chain to hold a top on the fluid reservoir/expansion tank. That doens't work at all well,...
Fuel Injector Rebuild
In 2005 when we build the car we had the fuel injectors out, added new o-rings and gave them run in an ultrasonic cleaner. They are now 33 years old...
Oil Filter Housing Plug Replacement
The M20 engine leaks oil, this is one of the places it started leaking from recently. The housing which the oil filter connects to and the oil cooler pipes has...
Vacuum Leak Testing Smoke Machine
I watched this video from martinbuilt showing a DIY build, after seeing a pro grade unit being demoed used by the Car Wizard in his essential shop tools video. The...
Coolant Expansion Tank
Purchased a new coolant expansion / header tank to replace the original 1988 part from the donor car. For the first time since building the car you can see the...
Heater Fan Fix
For a number of years now the heater has caused problems with the fans moving out on the shaft and scraping against the side of the outer casing. The tick...
Rear Brake Pressure Regulator
Someone pointed out the stock BMW rear brake pressure regulator was incorrectly mounted on the car. Not sure if this made much difference as it has always worked. However decided...