Norfolkluegojnr
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| posted on 11/7/14 at 08:03 AM |
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quote:
Originally posted by TimC
Just a heads-up for anyone who might fancy joining our gang, there's a Gemini on eBay at the moment:
It's on eBay and is nothing to do with me!
Yes I saw that. Looks decent from the pics, but could do with a few more! 
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Norfolkluegojnr
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| posted on 20/8/14 at 09:16 AM |
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Thought it was time for a quick update - i've had various threads running with various issues, but I haven't updated the build thread in a
while.
So, after the above, I took the car for its first MOT. First dissapointment was it was running very rough, misfiring, sounding like its running on
three or two cylinders.
Managed to limp to the test centre, and only failed on a sticky rear drum! More on that later.
Once back home, I set about figuring what was causing the rough running. Firstly, checked the timing - all ok there. 10deg at idle, advancing to
roughly 36 at 4k.
So, new leads, points, coil, cap, rotor arm and plugs fitted, and gap set. BritishTrident kindly pointed out I had the wrong points in the dizzy:
New ones now in, but forgot to take a pic.
After all electrical updates, there was no difference to the running at all. Well at least it ruled that out!
Being fairly sure now the issue was fuel related, I set about checking my Dellorto 40 twin carbs. I immediately decided they are made using
witchcraft, and that a change to bike carbs was in order.
In reality, I'm sure the Dellortos would offer a great option, but they are just too complex and expensive for me to service. They'll be
up for sale soon.
So, a quick email to Fastdan of Danstengineering, and this landed on my doorstep:
Very pleased with the service and price, and I'd be happy to recommend Dan to anyone else requiring bike carbs and manifolds.
Dan recommended using ZZR600 carbs, as the spacing is similar to the ports on a crossflow, so I went with his wisdom. Starting with 150 main jets, I
expect I may need smaller, but I’d rather overfuel to begin with than risk running lean.
Firstly then, to take off the float bowls and change the jets:
Current ones in there were 142, so may well be useful. Carefully cleaned and put away.
Time to get the manifold on then:
As you can see, fits perfectly, and leaves plenty of room for the carbs:
Started fitting the throttle cable and cold start cable, but ran out of time.
More updates to follow shortly, but pleased with last nights progress.
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Dick Axtell
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| posted on 20/8/14 at 11:08 AM |
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Carbs Support??
Hi. Been following your progress with interest. Do your bike carbs simply hang off the manifold headers, or have you fitted a separate support brkt?
Work-in-Progress: Changed to Zetec + T9. Still trying!!
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Norfolkluegojnr
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| posted on 20/8/14 at 11:14 AM |
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quote:
Originally posted by Dick Axtell
Hi. Been following your progress with interest. Do your bike carbs simply hang off the manifold headers, or have you fitted a separate support brkt?
they just hang off, but its not as bad as it sounds!
the proper fluoro lined hoses are very thick and quite stiff. With decent clamps, they are very secure.
Equally, the carbs weigh less than half that of the Dellorto's, so really no issue at all. A tried and tested method!
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Dick Axtell
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| posted on 20/8/14 at 12:46 PM |
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Thanks for confirming that!
Work-in-Progress: Changed to Zetec + T9. Still trying!!
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Norfolkluegojnr
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| posted on 24/9/14 at 10:29 PM |
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update pics. Will do a write up tomorrow:
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Norfolkluegojnr
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| posted on 25/9/14 at 07:35 PM |
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So, after a busy summer, including visiting Monza for the F1 weekend, i'm back on the trail.
I've been trying to get the carbs to run and having an absolute nightmare. I balanced the carbs up, set the idle screws to 3 turns out, and it
fired up nicely - shortly after it seemed to be rocking and stumbling. After diagnosing no ignition using a colour tune, i took the carbs off, cleaned
the jets and refitted - fired up lovely.
This cycle continued four or five times with a different pilot jet getting blocked each time. So, this week I took the carbs off, and stripped them
down completely and cleaned with Wynns. I've replaced the fuel pipe and added another filter.
I've bought replacement jets, which havent arrived yet, but as soon as they do it should just be a case of reassembling, and balancing again.
Fingers crossed all.
I the meantime, I've painted the rocker cover, and wrapped the exhaust. Next up is replacing the radiator and fitting the elec fan. Then,
I'll be fitting a wideband to assist with tuning.
Aiming to be on the road and reliable for next years shows!
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TimC
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| posted on 9/12/14 at 09:47 PM |
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Any updates?
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Norfolkluegojnr
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| posted on 10/12/14 at 10:04 PM |
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Sorry, life getting in the way of cars. Must see to that.
SO the jets arrived and I rebuilt the carbs, being careful to dissasemble completely, and reassemble with having cleaned every component as best I
could in the garage. All back together and on the car.
A few frustrating days fiddling with balancing and it seems to be running fairly well. on tick over it was getting very hot so it was time to replace
the rad. on removing the pipework and radiator, it appears that the pump was barely working with both heater pipes completely blocked, ad the main
feed to the rad only just getting any water through it.
New pump ordered and fitted from Burton, and its on with the polo rad install, kindly donated by another locost member. I used the fan switch from a
fiat panda (87-92 temp range) and a SPAL fan I had on the shelf. All fitted and run up to temp - working lovely. I also too the time to fit an
expansion tank to help, and an inline filler from CBS.
Also too the time here to tidy up wiring, wrap the manifold and re-site the horn. Also fair bit of rubbing down and painting to tidy up some of the
rusty parts. I then fitted the sausage filter which need a small amount of modification, refitted the fuel lines and throttle cable, and fitted an
extra return spring for the throttle to give it some more feel.
Finally was sorting the sticking handbrake. Very simply, the rod which connects the hub to the cable was pressed against a chassis member, leading it
to stick on. A simply fix was to drill an additional hole in the level arm, and to refit the rod a little higher up, so as to kill the rubbing. God
knows how it passed an MOT previously like this.
Sorry for lack of pics, i'll take some more this weekend.
So, that brings us up to date I think, Still needs tuning which I'll arrange with Bailey shortly, but a quick run around on a private road and
it seems to be working rather well:
 [/URL]
lots more to do, but hopefully will be usable for summer now!
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Angel Acevedo
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| posted on 12/12/14 at 12:36 PM |
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quote:
Originally posted by Norfolkluegojnr
quote:
Originally posted by Gemini
You probably dont need to worry about a heater,my exhaust keeps me warm!!
How is your exhaust, mine gets very hot and i keep cutting additional cooling vents to try sort it.
With respect to the master cylinder,keep it as is or maybe change resivoir to remote ones. as long as the cap can come off and you can check levels it
would be fine as long as the body is not putting any pressure on it.
[Edited on 1/6/14 by Gemini]
More about passing MOT than actually heating! Demister needed I believe, so now repaired.
Exhaust wise I can't really comment yet as I haven't had it running for any length of time. Where is in better hot? In the side pod?
Master cylinder is a head scratcher. It's only fillable with the cylinder loosened, not exactly ideal. Once MOT is passed, I'll reassess
over winter I think.
Couldn't you alter installation angle?
This may need altering pedal angle/travel..
HTH
AA
Beware of what you wish.. for it may come true....
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alfas
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| posted on 16/12/14 at 10:50 PM |
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i remember on my gemini the postition of the master was much more forward...easy to fill..even the angle was a bit steep.(similar yours)
but a big disadvantage: due to the position of the master it was impossible fitting double sidedraughts, even bike-carbs was impossible.
another roblem on mine: rear suspension was a bit a problem: on full rebound the axle was hitting the chassis...more or less the shock was end of
stroke and in the same time the axle tube was slightly touching the chassis
[Edited on 16/12/14 by alfas]
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Norfolkluegojnr
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| posted on 29/12/14 at 06:21 PM |
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Quick update - I've put the Gemini in for MOT tomorrow morning, so wish me luck!
Aim is to have the car tuned in Jan/Feb so I'm ready for summer. Considering a potential zetec install next year, but that can wait for now.
Hoping the MoT goes ok, amd I can get some miles on the old girl.
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TimC
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| posted on 29/12/14 at 09:39 PM |
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Good Luck!
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HowardB
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| posted on 29/12/14 at 09:41 PM |
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Good luck
Howard
Fisher Fury was 2000 Zetec - now a 1600 (it Lives again and goes zoom)
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alfas
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| posted on 29/12/14 at 09:51 PM |
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by the way: is there any gemini for sale?
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talkingcars
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| posted on 30/12/14 at 12:59 AM |
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Good luck with the MOT.
I think the demister is required for the IVA test, not the MOT.
I noticed the other day that Maplin sell little 12v ceramic demisters for £12.
I also think the heater box is from a mini. A lot of modern cars have the fan and heater matrix off set with just a distrabution box in the centre of
the dash.
I was going to say that you could undo the bolts holding on the master cylinder to access the resivour (sp) but you've already sussed that. You
could go for a set up lke the MGF where the brake servo and master are offset to the other side, as if the car was designed as a left hand drive.
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Norfolkluegojnr
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| posted on 30/12/14 at 10:40 PM |
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Bloody frozen, but VERY happy..........
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talkingcars
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| posted on 31/12/14 at 06:45 PM |
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Nice one - get it taxed and use it - LOL.
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Dick Axtell
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| posted on 1/1/15 at 12:01 PM |
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quote:
Originally posted by Norfolkluegojnr
Sorry, life getting in the way of cars. Must see to that.
Doesn't it just??
quote:
SO the jets arrived and I rebuilt the carbs, being careful to dissasemble completely, and reassemble with having cleaned every component as
best I could in the garage. All back together and on the car.
Having noted that your bike carbs look very similar to mine, can you tell me (i) where you obtained your replacement jets, (ii) what size are they,
and (iii) lastly how was the new jet size determined??
Thanks in advance.
Work-in-Progress: Changed to Zetec + T9. Still trying!!
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Norfolkluegojnr
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| posted on 2/1/15 at 09:02 AM |
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quote:
Originally posted by Dick Axtell
quote:
Originally posted by Norfolkluegojnr
Sorry, life getting in the way of cars. Must see to that.
Doesn't it just??
quote:
SO the jets arrived and I rebuilt the carbs, being careful to dissasemble completely, and reassemble with having cleaned every component as
best I could in the garage. All back together and on the car.
Having noted that your bike carbs look very similar to mine, can you tell me (i) where you obtained your replacement jets, (ii) what size are they,
and (iii) lastly how was the new jet size determined??
Thanks in advance.
I bought the jets from FASTdan when I bought the carbs and the manifold - link
I have also bought bits from this guy on ebay, he's super fast and great at responding. is in Holland though!
link
Size wise, they are 150's, which Dan reccomended as a good starting point. On initial run down the road they seem ok, but until I get a lambda
plugged in I won't know for sure. it revs cleanly through the range, so cant be to far out.
if you need any help let me know, I've taken them apart quite a few times now!
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Dick Axtell
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| posted on 2/1/15 at 09:45 AM |
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Thanks very much for these tips.
Work-in-Progress: Changed to Zetec + T9. Still trying!!
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Dick Axtell
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| posted on 8/9/15 at 02:35 PM |
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Another Q!
Maybe you can help on this irritating TPS matter, as you have the same bike carbs -
http://www.locostbuilders.co.uk/viewthread.php?tid=200174.
Just realised my assumption here. With your Xflow, are you using a TPS on your set-up?
Work-in-Progress: Changed to Zetec + T9. Still trying!!
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rgb247
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| posted on 11/8/16 at 09:00 PM |
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Hello all.
I've just bought this Gemini from 'Norfolkluegojnr' so rather than start a new thread i thought i'd continue with this one.
So far the standard oil, water, fan belt change. Went for 20W50 oil as that seems to be recommended for modified xflow engines. Now have a small pile
of parts accumulated ready to go on this weekend. Will post as I fit them.
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rgb247
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| posted on 12/8/16 at 07:54 PM |
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Couple of jobs done. New pin clips from Sparco to hold the bonnet down instead of the frustrating screws. And new starter motor, apparently uprated
50% on the original. The old starter was quite grotty and slow to turn over when i tried to do a compression test. This one is noticeably more
powerful.
 
Starter motor from aapoldham
 
Bonnet clips from Sparco
Stopped tonight by the engine mounts. I can get the bolts to the mounts undone but not the rubber isolator itself, just twisting not coming off.
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rgb247
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| posted on 15/9/16 at 09:26 PM |
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Quick update. Measured the clearance at the bottom of the sump at 5.5cm which isn't great with a couple of speed bumps between me and work.
After changing the engine mounts i've got enough to clear them just need to get under the car again to measure it for an exact number. Any
higher and the oil filler cap and air filter hit the bonnet so it'll have to do.
Old clearance
 
Oid Clearance
Next big job was rewiring. After melting another fuse it was time to sort it out. I got a new part loom and fuse box with plenty of circuits and set
about getting my head around the old one. It was an old Escort MK2 fuse box but along the way a electric fan, fuel pump and extra gauges had all been
put on the same circuit as the coil and a few other things... starting to see why i was going though fuses like petrol. Old box out, new box in
putting everything onto its own circuit and adding relays for the fan and fuel pump.
New fuse box & loom
 
New loom
Taken it out a few days this week and it's not missed a beat. While i'm in an electrical mood it's time to try and get the speedo
working, plan is to get a passenger with a multimeter to check i'm getting a signal from the sender. If i can get my current gauge working
i'm contemplating a new dash layout. Some nice brushed steel is my favourite at the moment.
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