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Got the bumper and old cross member off. Was pretty tricky as the headlights wouldn't come off due to the two small bolts on each just spinning the square nut inside the plastic housing. Eventually got the bumper off... had a victory beer lol. The cross member is spot welded (through holes) in...

Haha, one thing I don't have, but as luck would have it the missus has one :D

Arrived today :) excited about getting it on, not looking forward to getting old one off lol. Will I need more than sockets/spanners and an angle grinder for my rust seized 96 K11? Removing the exhaust involved cutting the middle section with a cutting disc! Anything to mind when...

Sounds around about the gist from the guide on here (bit tricky to follow without pics). I got pretty close to figuring out getting the bumper off, I think taking the headlights off would let me see and get to the last few illusive screws! I could definitely get it off trying a second time...

Does it bolt on before you weld it? Like could I fit a new one just with the bolts and then drive to a garage to get them to weld it? I don't have any welding skills nor mates with them to ask a favour, or borrow and try to learn...

Finally got round to sorting a few things out today. Did the exhaust blow test to try and find a leak and couldn't find anything! There was a burning oil/fumes smell around the manifold... Turned out to be a combination of a small patch of oil that had dripped off the dipstick, and some grease...

Just ordered one through yer site. Thanks in advance for making these! :)

Getting my mod on...

Another day, another lunch time in the car park, lol I moved the carbon canister down until it was held by just the last few mm of the circular clamp bracket, and that let the Almera box sit pretty much horizontal. The new box's mounting tab with the screw hole is resting on the crankcase...

I was running over my hour lunch break and hadn't eaten yet, so didn't even attempt to shift it lol, should be ok to move though when I get some time. I played around with moving the fuel filter and bracket when I changed it out for a new one that was a different size, and that worked out ok...

Right, I got an airbox courtesy of nexussteve (thanks btw :D ) Managed to get the old intake pipe out (battery bracket looks like it would need a few hours penetrant lol) with some jiggling of the coolant tank. Got the stock airbox off and fitted the GA16 airbox, connecting the small ~5mm...

Ta. Will give that a go if I can't see it billowing out with the tail blocked lol

It smells like exhaust inside the car with the fans on and the vents switched to pull in outside non recirculated air. If, after changing out the washers so that they all fit flat, and doing some blowing tests a la Haynes manual, I can't see any smoke, has anyone got pointers on what to check...

I see cross member sections on eBay for 30 or 40 quid. Some state they are insurance approved. I guess these are fine as replacements and I can just buy one, strip the front as much as I can and take it to a garage for welding?

Cool, well thanks for all the pointers, got it on tonight, mostly after sunset lol, but I'll have to change out the manifold washers as there's a random mix of original and some I had. One of the studs might be almost stripped as the nut became easier to turn and I didn't want to force it. No...

Good good... cheers :)

So not a death wish drive then?

Was such a pig to get the old exhaust off... almost all the bolts were seized despite 3 days of soaking, and using a torque wrench as a driver for leverage... ended up cutting it in the middle with an angle grinder and then shimmy/turning/wiggling the two bits (down pipe to middle, middle to...

While removing the manifold and exhaust today, I noticed one of the bolt points of the central section of the cross member is quite severely rusted. I know this means I need a new cross-member/frame section, but what I'm asking is, Is this dangerous to continue driving on for a week or so...

Ok I'll look out for where one would go when I lay out the Janspeed system in the morning. The belt(s) are squeaky, and the alternator looks old so I'll be taking a gander at them while they're off. After cleaning up the alternator, would I want to use regular grease, or dielectric, or copper...