Lewis's Banana Boat

Do you have a Puma that is a project? Do you want to track the progress with your own thread? Feel free to do it here.

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Lewisrowezer
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Lewis's Banana Boat

Post by Lewisrowezer » Mon Aug 19, 2019 7:58 pm

Hey all, I started my puma journey on the 6th July and regret not opening up this project thread earlier.

I'm a really big fan of cars that can "do it all" whether that's daily, fast road, track, rally, drag or show use and the puma ticks all of those boxes for me. I didn't originally like the Puma and thought it was a very ugly duckling but as time went on I've grown very fond of it. Jumping into the puma almost felt like home after having owned 8 Fiestas and absolutely nothing else, but owning something as limited as the Millennium definitely enhances that feeling and makes me feel like I own something genuinely unique.

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The Millennium itself was in the pipeline for a little while but I never found one that fit my budget. They were all 1.5k+ and they were dreamer figures considering my outgoings. One popped up on Gumtree for £650 and after a nice talk with the previous owner on the phone at 11pm (Yes I was that desperate to get in on it) I managed to seal the deal and I'm very glad I did. The owner was in his 80's! I was extremely lucky to have found the previous owner Roger on Gumtree as he held the car for me for 2 weeks with no deposit even after receiving offers in excess of £1500 and proved these offers to me via emails. A seriously genuine guy, safe to say you simply DO NOT come across people like this every day. After the 3 hour drive to Cambridgeshire the car was now under my name and I was ecstatic.

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The car stands out on the road by all means, love it or hate it you can't forget the bright yellow silhouette (My favourite colour) but there are definitely a few design features which I would like to "enhance". Before I start running before I can walk I'd like to touch on a few things that I have done so far in my month and a bit time of ownership. I work at ford and being a parts man I get genuine service items for dirt cheap. *WARNING BIG LIST*

Service Wise:
  • Oil + Filter - Genuine
  • Sump Plug - Genuine
  • Air Filter - Genuine
  • Fuel Filter - Genuine
  • Pollen Filter - Genuine
  • Spark Plugs gapped @ 1.0mm - Genuine
  • Accel Coil Pack
  • Magnecor HT Leads
  • Power steering bleed + top up
  • Greased hinged
  • MAF Cleaned
  • Throttle body polished + springs lubricated
  • Clutch bled
  • Alignment done
  • Droplinks done
  • Idle control valve cleaned
  • Air conditioning re-gas
  • Rear wiper - Genuine
Repairs Done:
  • Broken Tailgate latch replaced w/fully working Scrapyard part
  • Central locking fixed by fixing aforementioned part
  • OSR Wheel bearing replaced with genuine Ford part
  • Handbrake cables replaced with genuine ford part
  • Aerial Replaced with genuine Ford part
Repairs Pending:
  • New gearbox to fix neutral return spring (Already bought)
  • New OSF lower arm fitted
  • Central locking temperamental
I won't talk too much about the plans with the car right now, just an up to speed on where we're at now from purchasing the vehicle :) Speak soon - Lewis
Last edited by Cherie on Mon Aug 19, 2019 8:28 pm, edited 1 time in total.
Reason: fixed image links
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evilrob
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Lewis's Banana Boat

Post by evilrob » Mon Aug 19, 2019 11:20 pm

Hi and welcome! I will be following this thread with interest! :thumbs:
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red
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Lewis's Banana Boat

Post by red » Mon Aug 19, 2019 11:22 pm

Nice introduction, look forward to seeing the progress! Everyone loves a Millennium edition.
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Van_Dammesque
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Lewis's Banana Boat

Post by Van_Dammesque » Tue Aug 20, 2019 8:16 pm

:-D did you wear them shoes to match?! :lol:

:ok:
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zinc2000
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Lewis's Banana Boat

Post by zinc2000 » Wed Aug 21, 2019 12:16 pm

Nice!!! but then of course I am slightly biased
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Empty Scottish roads and a Puma, bring it on

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PhilLew
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Lewis's Banana Boat

Post by PhilLew » Wed Aug 21, 2019 5:24 pm

hi, welocme along! :grin:
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Lewisrowezer
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Lewis's Banana Boat

Post by Lewisrowezer » Wed Aug 21, 2019 9:02 pm

Thanks all :-)

A little up to scratch on the past couple of days!

First of all I received a little order from Ebay, just a little touch but really happy with it :)
31.jpg
In car pic:
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Changed out the NSF Lower arm the other day, spent about 3 hours chiselling away the top nut on the rear bush because it was rounded to hell! OSF Lower arm is painted and awaiting fitting but the bolt had physically sheared off on the bottom flush with the arm so a angle grinder/reciprocating saw will be needed to cut the arm off prior to fitting that one. Arms are Starline from Eurocarparts and I painted them in Hammerite Smooth Yellow :wink:
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Replacement Genuine Ford Rear Arm bolts FINIS Code 1038960 (Bolt) and FINIS Code 6797866 (Nut):
6.jpg
Among those little bits I've also managed to source a 1.7 Gearbox for £50 to fix the neutral return spring issue, considering the neutral return spring is a gearbox apart jobbie I refuse to take that job on and for the sake of £50 for a fully working gearbox I decided that would be the better option.
7.jpg
My plans with this gearbox freshen up job:
  • Focus 1.8 LUK Clutch
  • Genuine 1.7 Slave Cylinder
  • New Driveshafts (Ebay)
  • New Driveshaft Oil Seals FINIS Code 1805715
  • Castrol Syntrans 75W90 Gearbox Oil
  • Gloss Black Transmission Cover Powdercoated
  • E-Tech Yellow Painted Gearbox
I've already gotten started on the little tidy up:
8.jpg
While my main focal point is the gearbox at the moment, I'm also planning to collect a genuine 909 Evo spoiler within the next few weeks for the car which will be sweet and add a lot of shape to the rear end, more on that soon!
Last edited by Lewisrowezer on Wed Aug 21, 2019 9:21 pm, edited 2 times in total.
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Lewis's Banana Boat

Post by Cherie » Wed Aug 21, 2019 9:18 pm

Your image links aren't working as the [ img] tags only work for direct links to jpeg images. You need to go to the Page you've linked to, right click the image and select 'Copy Image Address' and post that with [ img] tags either side:

Code: Select all

[img]https://i.imgur.com/GSp94M5.jpg[/img]
Image
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Lewisrowezer
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Lewis's Banana Boat

Post by Lewisrowezer » Fri Aug 23, 2019 9:59 pm

Update;

Gearbox primed up and painted, I used a Zinc primer to prevent corrosion and it turned out quite well!

Image

Decided to paint it in RAL5012 Blue instead, Halfords Gadget Blue Enamel paint, the yellow looked naff! Painted and Lacquered:
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That's the box work done for the meantime, just a little clean up and a little colour until I get ahold of the other bits I need.

I forgot to mention I also gave the engine cover a respray and it looks amazing, I used Halfords Ford Stardust Silver and Lacquer:

Image

With that out of the way, I've come across a HUGE problem. My brakes have completely stopped working over the past day. When I put my foot on the brake pedal nothing happens until my foot is flat on the floor :evil: I suspect recent work on the arms may have caused the issue so for now I've just picked up some Pagid brake hoses and 3L of DOT4
Image
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Going to get the car off the ground tomorrow, have a good look about, replace the lines and remove the servo/master to investigate.
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Lewis's Banana Boat

Post by Orphan » Fri Aug 23, 2019 11:53 pm

It's getting along nicely.
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Lewisrowezer
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Post by Lewisrowezer » Sat Aug 24, 2019 11:48 pm

Fitted the new lines today, was so busy and dirty I didn't get the chance to take a picture. Unfortunately the new lines didn't fix the issues I was having on the front brakes so the master cylinder was removed for investigation. There was no brake fluid getting to the front brake lines.

We didn't find anything too fishy until my friend noticed the master leaking very slightly where it meets the servo. The car is now off the road until I decide what to do, I've asked around in hope to find a direct replacement servo and master cylinder in full working order but it may be more along the lines of changing to the newer style servo and master cylinder as the latter is much easier to get hands on..Massive pain as I'm having to insure my track car for daily use now!
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Post by Lewisrowezer » Tue Aug 27, 2019 8:58 pm

Problem = Solved!

Turned out the problem was the master cylinder in the end, thought the car would be off the road for quite a while but after a little drive to Basingstoke I managed to pull a "newer style" servo off a Fiesta along with the ABS pipes and master cylinder. Here's the setup from before:

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Replacement newer style servo, master cylinder and abs lines fitted (Clutch pipe required a little bit of bending to fit)
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Very happy to have the car on the road again and so quickly, originally after fitting the new bits the brakes didn't work after bleeding so I hooked up my ezibleed kit to the spare tyre and bled all 4 brakes starting from rear right and worked my way to the rear left, front right and finally front left whilst giving the pressure bleed/flush tool a helping hand by pumping the pedal manually too!

Little bay pic
Image

Now I can focus on the gearbox :o
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Lewis's Banana Boat

Post by N1X » Wed Aug 28, 2019 8:58 am

Hi !

Fantastic looking millennium you have there.
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Post by Orphan » Wed Aug 28, 2019 11:02 am

What Fiesta was the donor of the new parts?

Which generation?

Just in case i run into this problem in the future.
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Post by zinc2000 » Wed Aug 28, 2019 1:20 pm

Hate this car, its cleaner than mine and to add insult to injury he is using the damn thing as well :lol:

Cracking wee motor, top job mate :thumbs:
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Empty Scottish roads and a Puma, bring it on

Lewisrowezer
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Lewis's Banana Boat

Post by Lewisrowezer » Thu Aug 29, 2019 8:27 am

N1X wrote:
Wed Aug 28, 2019 8:58 am
Hi !

Fantastic looking millennium you have there.
Thank you! :)
Orphan wrote:
Wed Aug 28, 2019 11:02 am
What Fiesta was the donor of the new parts?

Which generation?

Just in case i run into this problem in the future.
It was a MK5 Fiesta 1.25 (used to be puma swapped) If this happens to you and you can't find an older style servo/master then you'll need the Servo, master (don't seperate them unless you have a replacement seal), the lines from the master to the ABS box and the vacuum hose from the intake manifold to the newer style servo.
zinc2000 wrote:
Wed Aug 28, 2019 1:20 pm
Hate this car, its cleaner than mine and to add insult to injury he is using the damn thing as well :lol:

Cracking wee motor, top job mate :thumbs:
Haha thanks man! It's clean but definitely some rough patches!
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Lewisrowezer
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Post by Lewisrowezer » Sat Aug 31, 2019 9:36 pm

Not sure where to start with this post, got quite a few bits and bobs done so it'll be quite a big one!

I decided to tidy up a spare MAF housing which I had which came out really well in the end, I'm going for a more OEM look in the engine bay now and want it to look as fresh as possible so starting with a few small paint ups (Throttle body, alternator etc..)and slowly working my way to the bigger bits (Intake manifold, full engine which will probably come along with a rebuild..)

Anyway I started off with a wire wheel on the drill and cleaned up the body, I then scuffed up the flanges with sandpaper, finished them off with a polisher on a drill, quick job but came out okay for something you'll never see! I then used Zinc primer and it turned out like this:

Image

I then painted it with Halfords Aluminium Engine Paint;
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After that I focused on the gearbox, got it all ready for fitting :grin:
Image

Couple of parts, grabbed a genuine slave cylinder and some aftermarket driveshaft seals;
Image
Image

Today the gearbox was fitted, had one of my good friends Scott around to help out and managed to get it all sorted properly after many hours of struggling and getting filthy :lol: In the end I veered away from the original plans and went with a OEM fit Sachs clutch from euros and MPM 75W-90 Gearbox fluid.

Before Fitting;
Image

After Fitting;
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Very happy with how it turned out, the neutral return spring actually does its job now and the clutch feels buttery smooth, bites 1mm off the floor! I have some tidying up to do, may put a coat of rattle can on the end cap as it's quite chipped and another coat of blue on the gearbox while it's on as it got scratched up whilst fitting as well as the lower arm but all in all a job well done :grin:

I thought I'd finish off this post with a pic of the bay which I took earlier, i'm also going to update my plans for the car in the original post.
Image
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Post by alex' » Tue Sep 03, 2019 8:40 pm

you do good work on this millennium ! ready for the road :thumbs:

i like this version of Puma, it's very original, but this color was unavailable in my country ... :(

but i have a question ... where do you find the accel coil pack ?
0 x
Alex' from the french Puma forum : http://www.planetepuma.com/index.php" onclick="window.open(this.href);return false;

Sorry for the possible spelling mistakes, I use google translator :-(

Lewisrowezer
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Lewis's Banana Boat

Post by Lewisrowezer » Sat Nov 02, 2019 7:24 pm

Haven't posted for a short time, apologies! Fast forward I've decided to take the puma off the road for a full restoration starting with the engine and bay!

During this hiatus I've had the wheels powdercoated in my favourite colour RAL5012 Blue, replaced the AWFUL starline wishbones I'd put on the car with genuine Ford ones and that's pretty much it.

Going forward and talking plans; My vision is to get the puma back to it's prime condition in terms of looks, performance and handling with slight upgrades to each. I really love this car and don't plan on ever getting rid of it so getting it to a show standard would really satisfy my tastebuds.

Plans for the Engine Bay:
Cleaned
Smoothed in areas
Rust (if any) tended to
Bare metal sand
Full bodyshop respray Zinc Yellow
Lacquer, cut back and ceramic coated.
Bulkhead heatwrapped
Cables tidied
Ancillary metals powdercoated/sprayed for rust prevention and ease of cleaning.
Brake servo restored in gloss black
Brake bar powdercoated copper.

Plans For Body:

Full respray
Rusty areas cut out + re-welded with fresh metal
Front window glass replaced
Underseal
Powder coating of metal parts in gloss black (Wipers).

Plans For Engine + Gearbox:
No block work because bottom end parts are impossible to find
Replacement of all gaskets and seals
Clean up of carbon deposits
Replacement of ignition components
Painted block (silver)
Powdercoated sump
Powdercoated pulleys
Gloss black painted plastics
Pro Hose set in Grey
POTENTIALLY a LMS180 Inlet
Wrinkle black rocker cover
Stainless 4-2-1 Exhaust Manifold Zircotec coated
Gearbox resprayed in silver...That's it lol
Driveshafts restored.

Plans For Suspension
Bilstein B4 OEM shocks
New standard springs if necessary
New Top mounts
Subframe Powdercoated
Steering rack cleaned and restored
Anti Roll Bar powdercoated
ARB Bushes replaced
Wheel bearings replaced
Hubs powdercoated
Steering ends replaced
Rear beam bushes replaced
Rear beam powdercoated
OMP lower front brace added

Plans For Brakes
ST150 Front calipers
ST150 Genuine Discs
Genuine pads
Braided brake lines Front + Rear

That's my plans! Interior won't be changing at all, it's pretty much mint the way it is! I predict this will take a couple of years to do at a nice pace but it's going to be an awesome Journey and can't wait to share it with you guys!
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Lewis's Banana Boat

Post by gingerdave » Sun Nov 03, 2019 10:06 pm

So that sounds like a big chunk out of £10k🤨
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2.3 diesel Sierra mine all it’s life
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And a Grey Fergie 1949 which is very very slow very

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