epic service 2.0 (nearly done)

[knpenny]

steering oil changed with a bit of help from ma new pela pump, brilliant tool, when i had the cove off under the rad i noticed it hasnt been underseald above the cove , so i got some rust converter and got some waxoyl on the way, that'll be the next bigish job, allways something but to be honest i'm really enjoying working on the bongo some new interior bulbs as i wasnt keep on the led's. On further inspection when i was having fun with the coolant alarm the rear part of the leisure battery bracket is snapped, so a quick weld or fashion a new one.

Got a nice guy at work who does wonders with body and paint offered to get rid of the surface rust on the rear arches in return for some work on a couple of cars, good guy. and give it a nice bit o paint too just for good measure.
Having a bit of trouble sourcing that bloody alt pulley (for a reasonable price) as my source is out of stock, however the part number corresponds with the same pulley on the rx7 so i'll decide on that next month.
Wired an external switch to the radio as it was on constant live feed so as not to mince the battery.
looking towards a solar panel for the roof and beleive there is a company that sells the especially for the bongo, tin top and aft good news.
And on yesterday plugged it in to the ac recharger at work and it nice n cool inside now, especially important over here as its been 24° plus for a couple of weeks. Shes staring to give me tingly feelings now, it must be love
i'm officially hooked

[TheLongRoad]

Sounds like a proper job. Just fitted a new rocker cover gasket to mine. Was lucky as everything came apart easy. Will let you know if I've fixed the minor leak or made it worse.

[knpenny]

if you used a good silicone based sealant (not too much) and the new seal, you should be good, covered over 700km since the seal change and no leak, fingers crossed for you dude i'll be honest it comes apart quite nicely which i didnt expect from a 160k bongo but i did kinda snap a plastic pipe above the maf (no idea what its for) but a bit of super glue and some of that sealant did the trick

did you change the air inlet seal too? that was nice and easy, i must admit the 2.0 is super simple in its makeup, love working on it.

got the alt pulley ordered with the pin bracket nut and spacer, so that should be it for the engine (for now) but got a bit of work underneath to do, when i was changing the steering oil when i took the under cover off i noticed that the big support bracket/beam that runs from side to side, has not been undersealed,. But thankfully its not rotted through, it does have a lot of surface rust, so that rust converter will come in handy, give it some of that after a quick sanding and got some Waxoyl on the way (2.5lts of) so that will be sorted before the middle of may, found a few un-undersealed patches (no too much) so will be doing all of that at same time (another day on the bongo, not in) but nothing mechanical wrong (again, for now)
By wednesday all the paint bits that have been started will be done. i should have taken pics before and after

If you need any servicing tips of ideas where to find hard to get parts just send a message, hopefully i can point you in the right direction, now wheres that whiskey

[knpenny]

Paint's done and looking goot, standard PT chaste white and no rust under the arches, Grand total of 45euros, and a bit of work for the guy who done the paint, i dont have the experiance in that department but he got new brakes a revrse camera stopped his engine leaking (in about 5 places) glow plugs mfd lights oil and filter change, so he's quite pleased.

2 more jobs, alt pulley and the little bits that go with it and the rad support refreshing and i suppose when i'm under the weebeast i'll waxoyl any other spots i notice that are naked.

Bring on the swivel seats and hopefully solar panel, but i'll have to see what fundage i have after may good times but. All the annoying crap's dealt with.

[TheLongRoad]

Sounds like a proper job. Just fitted a new rocker cover gasket to mine. Was lucky as everything came apart easy. Will let you know if I've fixed the minor leak or made it worse.

400 miles and no signs of a leak, so I think that's a 'jobs a good-un' and sorted. My skinny spare needs a paint, the new head unit needs fitting (which will no doubt develop into new speaker project) and the dangly rear fog has to go. Still a few jobs for me then. Glad your Bongo is getting sorted too.

[knpenny]

I agree i'm sick of repairing tha effin fog, i think i might attempt to get a wire into the back door and use the reflectors and convert into double fog or just replace the reflectors with bulbs. Have to wait and see. Did the japenese not use fogs?
Good job on the rocker gasket, not everyone gets it right first time

[knpenny]

Success got the message todag that the alt pulley is on its way with the pin, bracket, specer, bush and nut from japan direct (with a little help from a translating board) for just £72, not doing the belt as its just been done less than two weeks ago, pays to do a bit of (lots of) research online. Genuine parts too. Only downer is that they're going to take a week or so to arrive but i can put up with that.
Paint is finished too and she looks new (ish) just standard chaste white (arches done too)
Just the rad support de rusting and the naked bits underneath with underseal next week (will prep the weekend) and then everything service wise will be done,
happy days

[mikeonb4c]

Great to read of your progress

[knpenny]

have fashioned a bracket and getting ready to drill the bumper for placement of fog as i cant seem to fing red and white filliment bulbs and i dont have a space for the fog in the cluster, but its all good cos i really wanted a cental one, kinda the same line as the hondas (sticking to japanese theme)
Will try and post photos of it when i finish it tomorrow. Just the hole to do and about 5cm extention on the wire. thought i was on to a winner with the cluster but you know how it goes

[knpenny]

Tried to post image but its harder than blockbuster and crypton factor combined But the fog instalation went really well, dont like to blow my own trumpet but its bloody perfect

[knpenny]

Got that rad support beam/bracket sanded down today and a healthy dose of Fertan rust converter, will let that set in for 48h and give all the bare bits alongs with said bracket the underseal, after that just the altenator pulley and other bits attached to it and then she'll be ready for her epic 5000km plus trip.
starting here in franche-compte on to lille, after to salisbury(without nerve agent) then to isle of wight after 'and most important) BONGO BASH after stoke, then on to edinburgh, after oban then barra and uists and harris and skye (outer hebrides) and then all the way back down again.
And then another oil, oil filter and air filter change.
Cant wait Where's that whiskey gone

[knpenny]

Last week the alt idler pulley arrived and its changed, no probs with fitting, nice and easy
As for the rad support/cross member, yeserday had it in early at work and gave it a good dose of underseal...... then kida went mental and thought sod it, i had plenty of underseal left so i just went ahead and did everything
Then phil (the nice bodywork guy) came along with some stuff the french call corqrue (i think) and started pulling down the door seals and sprayed this stuff into/between the the skins above the door. He says that'll prevent rust from getting in above the doors, as i had the inner edges of where the door rests sandes down rust converted and repainted, he reckoned that where he sprayed the corqrue was where water had been running up the door seals and was potentially a future issue, nice guy phil

So i am happy to report that she is finally done and looking sexy as hell, next upgrades which will consist of
swivel seats front and bench center which are booked in for june with northstar conversions on isle of wight, solar panel, stonger suspension springs with 25% better rating for the extra weight and cos we dont have an aft, we're looking at this cool thing, roof box tent https://www.tent-box.com/uk/
I often look at the aft bongos and wish i had one until i seen this, its the perfect solution for bongos with no aft, it also means she stays below 2.0m so she's still a car on the european autoroutes and we pay less

[knpenny]

Here's a list of the jobs done:

full filters oil,air,fuel and cleaned gearbox filter, all fluids, steeing,coolant,diff oil,gearbox oil,engine oil, brake fluid and aircon refresh sparks
seals, inlet, rocker, sump, gearbox sump, new ht lead #4 Belts, timing, x2 aux belts, Both idler pulleys for the aux belts, water pump, headlights restored, new front fog twice (damn m6) full front bulbs, rear fog centralised into bumper, de rusting of arches and cross member, and any other places i found underneath, Re undersealed, front bumper sides and arches re painted as well as the bits inside the door and under the bonnet, coolant alarm, gpsbluetooth:usb:aux:touchscreen:sd card stereo with reverse camera, all runners and gutters gutted blinds off and cleaned (which was fun,not) thermostat, tracking, rear cluster repaired and machine polished.....phew, glad i had a whiskey or two on the way.

We bought the bongo last august and all but the stereo and tracking ahs been done since feb this year so i'm pretty chuffed.

If anyone needs some tips or advice on any of these jobs, dont hesitate to ask or P.M me, as all who haved helped with their great advice, i am happy to help, and really, all who i spoke to since i joined fury, a MASSIVE thanks and i owe you a beer at least at the bongo bash at stourport in june, I'm kevin and my missus is Amelie, i'll see you at the bash i hope
If i think of anything else or do any other jobs, i'll just edit this post. CHEERS ALL

[mikeonb4c]

Really great job you've done there

[knpenny]

well, we need to keep as many as these fantastic motors on the road as possible and preventitive is better then repair in my book, so cheers again for the support cant wait to see the epic sight of 160 bongos in the same place, it might even bring a tear to my eye
and the missus said she's gonna confiscate my bank card cos i'm sure to get some great ideas for upgrades at the bash