#ZedShed Vixen’s farewell build

[Lee]

It’s no secret I’ve just sold my Z3 and bought my old Z4 Coupe back, but there were some jobs that I really needed to do before the new owner can take full ownership. She’s been a very successful track toy the last few years and this didn’t come without the additional wear & tear. So I’ve agreed with the new owner included in the price a full subframe refresh, Diff rebuild to remove the common clonk, gearbox shift pins and a host of powder coating. I also agreed to get the front bumper sprayed as the previous sprayer did a poor job.

So first up we got the old girl up in the air removed the front bumper and sills. This is a very late 02 Zed and we noticed the panels had been sealed in round the edges, first time we’ve seen this.

the sills were actually in a fairly good condition. These will still be disposed of unless anyone needs them. The sills themselves on the car were really solid considering the 138,000 miles.

then the car itself. This will all be under sealed before the new sills go on.

also the rear subframe still sporting its rubber coating. We did a subframe removal 4 years ago but this was before we powder coated metalwork. Springs will be powder coated plain black, they’re HnR lowering springs.

brakes are looking tatty so they’re being replaced.

the new owner made the decision to buy the premium Z3 pack and this comes with the big boy brakes, he’ll also get another 4 sets of pads.

watch this space we’re dropping the subframe Friday.

 

[Paul Rice]

Must be the most thorough Pre delivery check up ever done. Well done Lee and enjoy your old/new coupe

 

[Jamie Macdonald]

Love this can't wait to drive her

 

[Lee]

Not many photos of the actual doing more photos of the done bit. We were all off work today so decided to pull the subframe.

We originally pulled the subframe in 2017 for some powerflex bushes so everything this time round came out very easily. we nearly broke our record of an hour n half.

first inspection looked good but we were soon proven wrong. Light surface rust in places.

we then noticed under the rubber coating in places it looked tatty. Once we removed the coating it was really bad.

you can see inside.

luckily we do have a good pair of arms in the cupboard so this can replaced. We have started keeping old arms and repairing them or welding up the holes after blasting so this will likely happen to this arm.

Disassembly didn’t take long.

strange as the rest of the coating is still in place.

diffs for days we gave the new owner the choice of ratio. 3.38 for acceleration or 3.15 for cruising.

underside now looking bare. Tank straps crumbled when I removed them.

Tomorrow we’ll pull the gearbox ready for new shift pins.
Everything’s now been ordered. Diff and powder coating being dropped off Monday morning.

 

[Lee]

Not to much to say. Paint was being laid on the bumper and sills today. We also fitted new gearbox indent pins so she should shift gears like a new box now.

pre bumper being painted.

Gearbox needs to be removed for the indent pin replacement.

first new pins being fitted.

then the ones that cause the gearstick lean.

finally new 5th gear going in. This is the cause of all the issues with these boxes. The ptfe liner breaks down.

full house of old pins.

it’s worth mentioning the diff builder called and found the pinion gear bearing had begun to collapse causing the clonk that could be heard in the diff. Seems to be this or the crush sleeve being the most common diff clonk causes at the moment.

 

[Lee]

Today’s been a day of buzzing around collecting parts with a sprinkle of assembly.

Body will be ready for collection tomorrow. Looking good.

we collected the powder coated bits. There was some holes in the first pair, luckily we had a spare for one side. The powder coaters offered us a fix for future swing arms, they said in future they can Zinc coat/cover the holes then powder coat. This might be a game changer for us.

next was some assembly work. New bushes and bearings.

swing arm bearings replaced. this arm you can see the holes in the spring pad. This is not an issue as the water just drains out the arms either side of the pad seat.

Shortly after both arms were fully assembled, sport new discs.

we also collected the diff today. The front bearing had started to collapse causing the excessive play, this then caused the clonk. New bearings, seals, and sleeve. She’s good to go clonk free. Even a quick coat of paint.

 

[Lee]

The last 3 days have been intense. Safe to say we finally made it. Cracking effort from everyone getting so much work done in so little time.

First assembly was the subframe sporting the rebuilt diff.

hour later she was in.

all shinny

We also collected the newly painted bodywork.

We also have everything a clean up, she was so dusty.

engine bay got a good wipe down

the powerflex bushes were removed and returned to stock. Now sitting at the height they should be. You can also see some under seal to the right.

next we got the wheels on and rolled her out. Lines looking crisp.

bumper.

relatively stock Sport interior.

brakes looking fresh through the wheels.

boom!

test drive success

Waiting now for the new owner

 

[GazHyde]

Probably the most thorough Pre Delivery Inspection any Zed has ever had!

 

[Jamie Macdonald]

Extremely appreciative of all the work, care and attention that has gone on before she comes to me! Class job guys as always! Vixen will be back at the Zedshed before long I'm sure of it....

 

[Jack Ratt]

Great job guys

 

[Mint]

Superb

 

[Lee]

Vixen has been back with us for a week for some minor work. She also had her yearly MOT. The steering rack had failed really badly so we needed to change for a known working rack.

Pulling back the boots showed them full of fluid.

luckily on the Z3’s a straight forward job to remove.

was then just waiting on our local breaker to arrive with a working rack. Strangely we also found the belly brace to be missing.

roll reversal, everything went back in lovely. Now dry thank god.

now sporting a belly brace.

warming up and burping the system.

this was the last little side job before Christmas.

 

[spurs fan in a coupe]

Poor little thing patched up again ready to go for another year!

 

[Witchsilver]

So totally amazed with your work here Lee - basically what I want to do to my zed, ready for summer!!!

I just need to get a clue where to start!!

 

[Jam03]

Just seen this car pop up for sale

 

[Jamie Macdonald]

Yeah but what's happened to the market!

 

[AntStark]

Saw you in Botley the other day mate ..car looked awesome as usual