JASAPP

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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Wild E. Coyote
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JASAPP

Postby Wild E. Coyote » Sun Nov 02, 2014 10:47 am

Hi everybody,

After some thinking and encouraged by my good friend Pumanoob, I have decided to post my journey with my puma so far. JASAPP? What it stands for? Just Another Sub Average Puma Project. Having seen miracles performed by some of the members here, my effort is waaaaaay off that standard and abilities hence the Jasapp!

Anyway, I went to buy my puma in Germany. I wanted a good example and went to collect in Bonn. That is just about 1000 km in one direction. It was (and still is) futura model, in apperance very similar to millennium edition as far as the interior goes (recaro seats, full leather interior). The colour is moondust silver.
So, after a nice drive to Bonn and back, here she was in my carport

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Standard car with F1 wheels. When I collected it was deep winter and going from Germany meant I7d need to pass thorugh Alps so I bought winter tyres before I went home with it; no way I would have passed through Alps without them!

Two weeks later, I had an accident: a deer jumped into me on a local road! :cry:
The end result:

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As the car was going to be repaired to get rid of the rust, not to much harm, except I had to buy a new headlamp…

Soon I prepped the car for the bodyshop.

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The worst of the rust was in VIN area. Went on to see my MOT tester to get advice on that. He said nothing to worry, just cut it out, repair the area beneath it and put it on top. He saw the car, the numbers are visible, no problems there! Phew, one worry less!

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The car at body shop. The usual rusty rear end was replaced with zinc coated 1.2 mm thick steel. Also, did it without the bended section inside which is causing the rust in the first place!

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Both sides done, the underbody as well, and sealed and sent off to paintshop. The car prepared for the spray job
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And the area hit by deer repaired

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The car after respray. I did respray everything except the roof. Thought of doing that as well, but since I have heated windscreen, and the guy doing the spray job said there was 10% possibility it would crack on taking down so decided against it. It is expensive as hell…

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Re: JASAPP

Postby Wild E. Coyote » Sun Nov 02, 2014 10:57 am

First thing to be done was retrim of steering wheel. In details: viewtopic.php?p=266268#p266268

Short version: I went from this

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to this

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Few steps…

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Re: JASAPP

Postby Neil » Sun Nov 02, 2014 11:00 am

Nice job :ok:
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Re: JASAPP

Postby Wild E. Coyote » Sun Nov 02, 2014 11:15 am

Next was the ICE installation. In detail here: viewtopic.php?p=275960#p275960

Everything was accoustically treated including the roof. The headunit was replaced with Alpine unit. Also put in the steering wheel remote controls from a Mk1 focus. Made custom A pillars for twitters and dressed it in alcantara. End result in few images

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The iPod is primary source of music
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Re: JASAPP

Postby Wild E. Coyote » Sun Nov 02, 2014 11:16 am

Neil wrote:Nice job :ok:


Cheers!

Also, had to do something about the rear drums… viewtopic.php?p=267506#p267506

Or, few images:
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Much better...
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Last edited by Wild E. Coyote on Sun Nov 02, 2014 1:50 pm, edited 1 time in total.
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Re: JASAPP

Postby Brian' » Sun Nov 02, 2014 11:23 am

Such a nice Puma :P - About the rust on the rear arches you said the bending section will create rust, How did you find out about this? My Puma will have a new piece of metal in the future and I was thinking about getting a bending section for the carpets, Have you had any problems with the carpet being lose inside the arches?
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Re: JASAPP

Postby Wild E. Coyote » Sun Nov 02, 2014 11:27 am

Thanks!

It will not create rust on itself, but will trap crap and moisture that in time lead to rust. No problems with carpet what so ever!
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Re: JASAPP

Postby Wild E. Coyote » Sun Nov 02, 2014 11:35 am

Come the summertime, took the car to our coast. It performed nicely, but on spirited drive downhill the brake pedal went soft. That was it, the car deserves better brakes…..

Queing for the ferry…

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Waiting at the port…
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Upgrade to ST150 brakes in detail can be found here: viewtopic.php?p=288840#p288840

Short version in few pictures

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Sandblasted
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Resprayed in owen
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Ready for assembly
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And on the car
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Re: JASAPP

Postby Wild E. Coyote » Sun Nov 02, 2014 11:42 am

Next on list was the rear disc conversion. It was much tougher nut to be crackered. Dead easy to put on the car, but ABS needs precision to operate as it should.
In detail here: viewtopic.php?p=302532#p302532

Pleased to say it works perfectly now!
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Re: JASAPP

Postby XAF » Sun Nov 02, 2014 1:32 pm

Awesome thread mate, and lovley car!

When my Puma's arches rotted away, I had while quarters put on, and you could see exactly how they rot. Sadly, it's a design flaw, not the carpet liners or lip in the arch (although this does get surface corrosion).

Basically, rainwater somehow runs down the inside, down and sits in the crevice between the inner wheel tub and the arch. A ready made disaster, Rot from the inside out rather that outside in. You could see the pathetic attempt of Ford to underseal the arches, and the spots where the underseal didn't reach is exactly where they rot out.

Keep up the thread!
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Re: JASAPP

Postby Wild E. Coyote » Sun Nov 02, 2014 1:39 pm

XAF wrote:Awesome thread mate, and lovley car!

When my Puma's arches rotted away, I had while quarters put on, and you could see exactly how they rot. Sadly, it's a design flaw, not the carpet liners or lip in the arch (although this does get surface corrosion).

Basically, rainwater somehow runs down the inside, down and sits in the crevice between the inner wheel tub and the arch. A ready made disaster, Rot from the inside out rather that outside in. You could see the pathetic attempt of Ford to underseal the arches, and the spots where the underseal didn't reach is exactly where they rot out.

Keep up the thread!


Cheers, mate!
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Re: JASAPP

Postby Wild E. Coyote » Sun Nov 02, 2014 1:45 pm

Didn't fancy the VIN plate sticker. So had the VIN plate made like it was supposed to be made. IN detail here: viewtopic.php?p=280864#p280864

Or, few images:

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And the end result engraved in 3 mm thick aluminium
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And in the car
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Re: JASAPP

Postby Wild E. Coyote » Sun Nov 02, 2014 2:07 pm

After that I just couldn't stand the fact that you can't open the boot while engine is running. Did the interior boot release mod using the fordka switch and descrption in how to section. Also, bothered to take pictures of it. To be found here: viewtopic.php?p=290639#p290639

Or just few images, as usual:

Switch you need to find in the boot and bring another +12V to it to open the bonnet
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Some soldering (messy, I admit. Now would just cut it and then resolder it to make it neater)
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If you get just the switch without the female plug, the female plug of the electric window mechanism is THE SAME and can be used
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As these images prove
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After that you just have to match it to this scheme (courtesy of Fordwiki)
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Soldering and matching the wires
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Took the signal from the light switch nearby, so the switch is illuminated at night and looks OEM
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Searching for a permanent 12V behind the radio
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Success!
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Positioning the switch using the negative cut in MDF
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Marked the opening to be cut (used stanley knife)
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And end product!
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Re: JASAPP

Postby Wild E. Coyote » Sun Nov 02, 2014 2:13 pm

Now and then take it to a blast and she takes it without a problem…. (not legal to be driving faster then 153 km/h here, but…. 8-) )
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Also, some wintery pictures from last winter
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And how she looked after a drive in those conditions
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Now the speed cameras wouldn't be a problem!
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Re: JASAPP

Postby red » Mon Nov 03, 2014 9:37 am

Cool thread :)
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Re: JASAPP

Postby TGPlayer1 » Mon Nov 03, 2014 11:13 am

Far from sub average. Some nice little bits, i like the boot switch mod.
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Re: JASAPP

Postby evilrob » Mon Nov 03, 2014 11:38 am

TGPlayer1 wrote:Far from sub average.

I agree. Thread should be renamed AAPP.
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Re: JASAPP

Postby Wild E. Coyote » Mon Nov 03, 2014 12:58 pm

Thanks for your kind words!
Perhaps now is time to say that since I bought the car have changed all shocks and front springs (stayed at OEM, you saw the snow, if the car was lowered it would be useless in those conditions). Also redid the rear bushes and have on my shelves the front set of bushes as well. After that is done, I hope the car would be back to as good as new standard!
Today just changed the oil and filters; I swear to you I can notice the change in engine note when the oil passes its prime. The sound becomes more metallic, if you know what I am trying to say? Anyway, always use the Formula F OEM oil (I can get it here dirt cheap) and change it with filter every 10.000 kms. After change the engine works like a charm on tickover 8-) <3
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Re: JASAPP

Postby Wild E. Coyote » Mon Nov 03, 2014 5:06 pm

Some more things I did to my car. Cleaned and painted MAF. The wire was brownish, cleaned it first with carburettor cleaner, and then with brake cleaner (carb cleaner leaves a lubricating film). It was clean after and the car is idling rock steady! Good improvement, and I'd swear the engine is more responsive too!

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Ready for painting…
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Painted
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And back in the car
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Did the same to the topmounts as they were rusty and bad looking
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Primed
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Painted in black
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And in place
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Re: JASAPP

Postby Wild E. Coyote » Mon Nov 03, 2014 5:06 pm

Had to change the HCV. It was operational, but the plastic fell appart. It happened on way to work, luckily I was just one minute from it so crawled to while the system was leaking.

This happened
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Someone asked which one is original. Bosch made it as this picture proves
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Bought the FeBi as it was the only one HCT they had in the store nearby and changed it on my lunch break. Made a show in parking yard while changing it, topped it with water, let the system get rid of air and that was it. Works!
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Re: JASAPP

Postby Wild E. Coyote » Mon Nov 03, 2014 5:47 pm

Improved the boot as well. Had new carpet made to measure, bought 4 VW luggage tie down eyes. VW does them best, I have to admit it, so I got foour of them drilled some holes and tapped them. Cut the carpet to measure and screwed them in and put elastic net over it. No more things flying around in my boot! 8-)
Also, got the LED light instead of pathetic original; LED is 10000 times better!

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And the light
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Re: JASAPP

Postby Wild E. Coyote » Mon Nov 03, 2014 5:50 pm

The other day tried to clean the exhaust end. It was dirty and not very nice. Used some Sonax polish for stainless steel and think it came out just fine. Massive improvement!

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Also, put an umbrella in the car. And it is a ford puma umbrella I had for years…. :wink:

Cut some opening in the floor carpet and pulled velcro through
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Placed the puma umbrella in place where it bothers noone
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And the umbrella itself in front of the car
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Last edited by Wild E. Coyote on Mon Nov 03, 2014 6:19 pm, edited 1 time in total.
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Re: JASAPP

Postby Wild E. Coyote » Mon Nov 03, 2014 6:00 pm

As the suspension is almost renewed completely, thought could do the same with gearbox. Bought one used in good nick from IanG, and took it apart.

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It was in very good condition, only the selector fork for the third gear has some wear on it. The previous owner must have driven the car with his hand resting on the gearstick or something, as everything else is in very good condition. Synchro rings are as good as new.
So, on with refurbishment.
These are the parts that will be replaced: the bearings (all 6 of them), the third gear selector, the driveshaft seals, the selector shaft seal, and the imput shaft seal together with the fifth gear housing gasket
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Cleaning the housing which was very dirty.
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Both parts together; the small one (the fifth gear and reverse housing) is already cleaned, the major part still not
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Ready for jetwashing
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After some major celaning involving the hot water jetwash, plenty of brake cleaner, even some Lidl dish washing detergent and wire brushing the two parts (temporary) bolted together
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Ready for priming
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And primed
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That is how she stands ATM, and all that hussle is just preparation for instaliing the LSD, of course :wink:
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Re: JASAPP

Postby evilrob » Mon Nov 03, 2014 9:13 pm

First dibs on the umbrella if/when you ever sell it. :D
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Re: JASAPP

Postby tuonokid » Mon Nov 03, 2014 9:22 pm

Top job Wild E!!!!
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