Zel's Eclectic Fleet Blog (Volvo, Rover, Trabant, Invacar & Occasional Distractions)

Post pictures and stories about your cars both present and past. Also post up "blogs" on your restoration projects - the more pictures the better! Note: blog-type threads often get few replies, but are often read by many members, and provide interest and motivation to other enthusiasts so don't be disappointed if you don't get many replies.
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Zelandeth
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Re: Zel's Fleet Blog...Rover, Renault, Peugeot, Trabant, Invacar & Sinclair C5

#1661 Post by Zelandeth »

About that wiring diagram...

This is what we started with.

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Not exactly user friendly.

After I'd been left alone with it for a few hours.

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Still needs a bit of tidying up, but isn't that several orders of magnitude easier to follow now? This is also a vastly scaled down version - the original is about 7000px wide, and currently has about ten layers as I'm still meddling with it.

Key to Item Numbers on the diagram - in a format you can actually scan through rather than a totally unformatted wall of text. Especially helpful as the sequence of numbering isn't exactly easy to follow in some areas.

1 Generator
2 Voltage Regulator
3 Ammeter
4 Battery
5 Starter Solenoid
6 Ignition Warning Light (Red)
7 Ignition Switch
8 Starter Motor
9 Clock Illumination
10 Speedometer Illumination
11 Grouped Instrument Illumination
12 Number Plate Light
13 Number Plate Light
14 LH Tail Light
15 LH Side Light
16 RH Side/Park Light
17 RH Tail/Park Light
18 Main Beam Warning Light
19 RH Head Lamp Main Beam
20 LH Head Lamp Main Beam
21 RH Head Lamp Dip Beam
22 LH Head Lamp Dip Beam
23 Heater Motor
24 Horns
25 Horn Push Switch
26 Parking/Side Light Switch
27 Boot Light Switch
28 Boot Light
29 Dash Illumination Rheostat
30 Panel Illumination Fuse (3A)
31 Side/Dip Head Lamp Switch
32 Side/Main Beam Foot Switch
33 Heater Motor Rheostat
34 Horn Relay
35 Fog/Spot Lamps – Where Fitted
36 Clock
37 Front Interior Light & Switch (combined unit)
38 Front LH Door Switch
39 Front RH Door Switch
40 Rear LH Door Switch
41 Rear Interior Light
42 Interior Light Switch LH
43 Rear RH Door Switch
44 Rear Interior Light
45 Interior Light Switch RH
46 Windscreen Washer Pump Motor
47 Windscreen Wiper and Washer Switch
48 Windscreen Wiper Motor
49 Fuses A2 and A4
50 Ignition Coil
51 Brake Light Switch
52 Reversing Light Switch
53 RH Indicator Tell Tale
54 Indicator Flasher Unit
55 Indicator Stalk
56 LH Indicator Tell Tale
57 Instrument Panel 10V Voltage Stabiliser
58 Coolant Temperature Gauge
59 Fuel Gauge
60 Fuel/Oil Level Selector Switch
61 N/A
62 Distributor
63 RH Brake Light
64 LH Brake Light
65 Reversing Light
66 LH Rear Indicator
67 LH Front Indicator
68 RH Front Indicator
69 RH Rear Indicator
70 Coolant Temperature Sender
71 Oil Level Sender
72 Fuel Level Sender
73 Oil Pressure Warning Light (Green)
74 Choke Warning Light (Amber)
75 Brake Fluid Level Float Switch
76 Fuel Main/Reserve Pump Selector Switch
77 Overdrive Fuse (35A)
78 Overdrive Solenoid
79 Overdrive Column Switch
80 Overdrive Throttle “Kickdown” Switch
81 Oil Pressure Switch
82 Choke Warning Light Thermoswitch
83 Brake Fluid Level and Handbrake Combined Warning Light
84 Handbrake Switch
85 Fuel Pump (Main)
86 Fuel Pump (Reserve)
87 Gearbox Overdrive Inhibitor Switch
88 Overdrive Relay

I think this was worth spending a couple of hours on as it will make continuing the detective work on what's been meddled with massively easier. Yes I probably could have found one if I kept digging long enough, but I definitely learned a lot more about the car's electrical system doing it this way
My website - aka. My *other* waste of time
Current fleet: 62 Rover 110. 73 AC Model-70. 84 Trabant 601S. 85 Sinclair C5. 88 Renault 25 Monaco. 07 Volvo V70 D5 SE.
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Zelandeth
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Re: Zel's Fleet Blog...Rover, Renault, Peugeot, Trabant, Invacar & Sinclair C5

#1662 Post by Zelandeth »

I had a sneaking suspicion that I was facing issues with the head gasket on the Rover. Primarily based on the amount of gurgling and nonsense from the radiator and the tendency for it to immediately violently dump about half the coolant the moment the thermostat opens.

Did a really quick and dirty test to see if I was dealing with combustion gases getting into the cooling system.

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While it might be a very crude test, it's pretty conclusive! That glove started to inflate the moment the engine was started. There's only one place that can be coming from, and that's the cylinders.

Not the end of the world. I want to change the water pump O-ring anyway, and the inlet manifold gasket is suspect, changing that will be orders of magnitude easier with the head off the car. At least I won't need to disturb the exhaust which is usually the thing I'd dread most when pulling a cylinder head.

Everything I should need is already in stock.

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Gasket is a little simpler than on modern engines...

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I guess before I do go pulling it apart I probably should check that all the head bolts are actually tight (with non composite gaskets like this it *can* actually be that simple sometimes) but I'm not expecting miracles. Worth checking though as I've no idea what work has been done to the engine beforehand. I need to pull the inlet valve cover to change the gasket anyway so may as well do that at the same time.

Project Pinball has taken a few steps towards functionality today in that I think everything needed to get the PC side up and running is now here.

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My plan is to get the absolute basics up and going first before we start worrying about the extras. Not least because my interface board isn't likely to turn up for at least a couple of weeks yet. That is essentially just building a PC into a massively oversized case and setting up some software though, so shouldn't be too difficult. Even if it does mean I need to do battle with Windows 11 for the first time which I'm really not looking forward to. At least once it's set up here I won't have any need to interact with it much beyond seeing startup and shutdown screens.
My website - aka. My *other* waste of time
Current fleet: 62 Rover 110. 73 AC Model-70. 84 Trabant 601S. 85 Sinclair C5. 88 Renault 25 Monaco. 07 Volvo V70 D5 SE.
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Zelandeth
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Re: Zel's Fleet Blog...Rover, Renault, Peugeot, Trabant, Invacar & Sinclair C5

#1663 Post by Zelandeth »

Finally got a chance to (very briefly before it started tipping it down) look at the Rover today. I can confirm that the head bolts are indeed tight (well as tight as spec anyway - all of 50 lb/ft for the big bolts and 30 for the little ones). Guess it's coming off then!

Looks clean enough though - well up here where it's easy to get to anyway - what's under the exhaust valve cover really will tell a more full story I think.

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My website - aka. My *other* waste of time
Current fleet: 62 Rover 110. 73 AC Model-70. 84 Trabant 601S. 85 Sinclair C5. 88 Renault 25 Monaco. 07 Volvo V70 D5 SE.
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Zelandeth
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Re: Zel's Fleet Blog...Rover, Renault, Peugeot, Trabant, Invacar & Sinclair C5

#1664 Post by Zelandeth »

Had a very quick look under the exhaust rocker cover this evening (I was literally just taking some stuff to the garage, wasn't even specifically looking to do anything car related).

Not as clean as things on the inlet side as you'd expect, but still very clean for the age of engine I think.

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Definitely not a horrible sludgy mess anyway.

I still love the valve gear on this engine.

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I was pretty sure the valve clearances were out given it's far more tappy than my last P4. Testing purely with my eyes says I'm right.

The clearances are meant to be 6 thou on the inlet and 10 on the exhaust, and they're all at more like 50 I'd say. Inlet should be set hot too, so are probably even further out! Not going to worry about that until after the head gasket has been changed obviously, but I reckon that will quieten the engine down a lot. No reason not to just do the exhaust side clearances anyway I guess given they're not going to be disturbed.
My website - aka. My *other* waste of time
Current fleet: 62 Rover 110. 73 AC Model-70. 84 Trabant 601S. 85 Sinclair C5. 88 Renault 25 Monaco. 07 Volvo V70 D5 SE.
rich.
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Re: Zel's Eclectic Fleet Blog (Volvo, Rover, Trabant, Invacar & Occasional Distractions)

#1665 Post by rich. »

Will you be fitting harder valve seats when the head is off?
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Re: Zel's Eclectic Fleet Blog (Volvo, Rover, Trabant, Invacar & Occasional Distractions)

#1666 Post by Zelandeth »

rich. wrote: Mon Jul 28, 2025 7:00 pm Will you be fitting harder valve seats when the head is off?
I've not been really aware of these engines being particularly renowned for exhaust valve seat recession so have just been leaving that side of things alone - though having the head off would only be half the job here given the exhaust valves live in the block. I ran with a lead replacement additive in the previous one, will just be doing the same here.

-- -- --

Okay, where the heck were we before I fell horrendously behind? Oh boy, all the way back in mid July. This is going to be a long one (again).

[] 19th July.

Some further progress was made a couple of days ago, though it wasn't maybe apparent at a glance.

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Quite a few things had actually been done.

The most obvious is that I sourced and installed a new display in the back box which fills the space far better. My measurements had indicated that a 27" panel would be pretty much perfect - I was right. This is good because that's a really common screen size. So much so that I was able to walk into Argos and get one for less than £50 after using a voucher I'd had sitting around for ages.

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Obviously when the machine is finished there will be a mask there to hide the remaining gap around the edges. I honestly can't make that smaller though - getting that panel in there (never mind attaching it to the back of the cabinet!) requires every millimetre of vertical space we have. Attaching it to the machine involved a lot of me standing on my head and being glad I have quite long arms and was able to reach up through the cable access between the body and head of the machine. I'll be finding splinters for days.

No photo to show it, but the main display is now securely attached to the board it sits on. This makes moving it around a bit less awkward and makes stowing it to one side far less precarious as it will stand securely against a wall now. It's astonishing how much room a 40" monitor takes up when you can only lay it flat on its back! I need to add a second prop to allow it to stand up in "car bonnet" mode as it's too heavy for the original one. Or maybe a pair of gas struts?

Up until now we had a whole plethora of cables coming out of various areas into a bundle of spaghetti on the floor to provide power. This has been resolved, and power is now delivered to the cabinet via the original cable entry point.

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This currently just leads to an extension lead attached to the back panel.

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Eventually we will have a proper junction box around here, with all the secondary power supplies turned on/off by a contractor triggered from the PC 12V rail. This will do for now though and is a vast improvement on the previous mess.

Major progress has been made with these buttons.

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In that they now have switches attached to them again. No silly micro switches or anything like that, proper pinball machine leaf switches.

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This is one of those silly little details that really is important in having it feel like the real thing to play. It's not even that they feel particularly nice to press, like the action on a decent keyboard, but they feel like the real thing and most importantly should give very consistent performance. The Pinscape controller is now here so I should be able to get these wired up and working soon.

The central display panel for the dot matrix display (DMD) used by most modern tables for score readout has now been secured in place and tidied up. A big part of that has been getting the original red acrylic(?) window cleaned up for reuse. I had flip flopped on using this as it did mean destroying the original silk screening on the back of it. However it was already in poor condition and honestly wouldn't be hard to reproduce with a transparency in the future if someone did want to restore it. Just a plain black field with some clear windows and a handful of text. I did take high resolution photos for future reference.

The remaining print wiped pretty much straight off with a bit of acetone.

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Most machines just have the amber neon discharge displayed without any colour filtering, Eight Ball Deluxe LE is a bit unusual in that it had a red filter on the displays. I quite like the idea of having the DMD be red on here as a bit of a nod to the original table. It's a monochrome display anyway so doesn't really make any practical difference - it'll just be red rather than reddish orange. The filter window also really well disguises the display panel when it's unlit.

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With the properly sized backglass display and cover back on the DMD it's starting to look a bit less thrown together now I think.

Figured you'd all appreciate a change from Attack from Mars as our example.

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Proportions always look a little bit off because I can't fit everything in with the camera where my eyes are, and that's where the point of view is set up for - the 3D effect is quite convincing when you're actually standing there.

Hopefully we'll have working flipper buttons tomorrow. Let's see how much MORE of a rat's nest I can turn the inside of the cabinet into...

-- -- --

20th July.

It's starting to get a bit busier in here.

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Let's say hello to the interface board. I've been referring to this as the Pinscape controller, which technically isn't actually accurate. It's a Pinscape *compatible* controller. The Pinscape is actually a specific open-source project originally based around an NXP KL25Z microcontroller board, which runs the Pinscape software. The creator makes available the necessary resources to make all of the hardware yourself but there are also a few companies making ready-to-go assemblies like this. This one came from Cleveland Software Designand even including shipping from the US was probably cheaper than I could build it myself by the time I'd scrounged up all the parts and had the boards made.

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This has been mounted on the panel that I believe the original mains transformer would have sat on. It wants to be near to the front of the machine and solidly mounted to ensure that the accelerator is able to get the most accurate readings.

This little board does quite a lot for us, providing the I/O for the following:

[] 14 button inputs.
[] Potentiometer input for ball launch plunger.
[] 12 PWM controlled outputs.
[] 2 Non PWM outputs.
[] Accelerometer.

As far as power goes in the cabinet I'm trying to make my life easier in future by using consistent colours for the DC side. Yellow for 12V, red for 5V and once we have it, orange for 24V. This will also be labelled inside the cabinet once we're done. Black will obviously be DC ground. Mains will be contained in separate looms and will be our usual blue/brown/green & yellow or normal three core flex - I'll be aiming ideally to keep that all white.

The board will have its own 12V DC supply added before we get any solenoids installed as I don't want to risk back EMF ending up on the PC's 12V rail, but for now I'm just stealing 12V from there as we're not ready to fit them yet. I do want to bring the PC 12V to the front of the table anyway as I'll be running both the coin slot illumination (which will double as our power indicator) and two intakes fans I'll soon install on the base of the table.

Initially I thought I was going to need to go shopping for cable today before remembering I still had this bunch sitting in the leftovers bag. Just about any colour I can think of in there, and in weights absolutely fine for our intended purpose. It's nice to reuse original parts where I can anyway.

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I'm not worrying too much about wiring tidiness at this stage and am keeping things pretty slack. I'll trim ends, route cables tidily and loom things together where appropriate once the layout of everything is finalised.

Of those 12 inputs so far we've only used two - for the flippers.

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As promised by the creators, it basically Just Worked. The Pinscape configuration tool loaded the software onto the KL25Z board in a couple of button clicks, and then the inputs configured in a couple of minutes. The controller encodes button presses either as keyboard or joystick/gamepad button presses. In this case they are being passed to the PC as left/right keyboard shift key presses. All of the inputs can be assigned to any key press or button you like. The accelerometer is handled really simply as well, the X/Y input being delivered to the PC by pretending to be a joystick. It's a clever way of doing it. The outputs are a little different, being handled by some software called the Direct Output Framework - which allows specific devices when triggered in the software to also activate your desired devices.

Time for a test run.

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Managed to last all of about 90 seconds on the first attempt. That's about normal for this thing though. It is an evil table. Brilliant but evil. One of Steve Ritchie's works of genius - and with a little practice it is immensely satisfying to play.

This one also shows why I like the idea of having the central display behind the red cover, as when you're playing a game that doesn't use it, it really does just disappear.

On the subject of scale, here's a demonstration of how close to the real size our simulated tables are. Here's a close up of the pop bumpers on Eight Ball Deluxe with the outer ring of one from the real table for comparison.

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Pretty close!

An area which computer games always struggled for years was lighting - and the various blinking lights on the playfield here would tend to just be areas that got brighter, not looking like they were being lit by actual lamps - we really do seem to have got past that now - here's a close look at a few on the lower playfield of the same table. Note how the ones which are lit with the more clear covers look like there are actual bulbs behind them.

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A similar shot of the playfield on Medusa also shows how well the lighting is rendered.

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Even if the camera has blown that one out a bit, you get the idea. It's small details like that which really do help make your brain forget that it's a screen you're looking at to some extent.

Probably not going to get a chance to work on this again for a few days as we've got guests staying until the middle of the week, but we're definitely making decent progress.

-- -- --

21st July.

Last time I had the Trabant out she was distinctly cranky, with a heavy miss under load. I had a feeling this was likely to be a fouled plug as I'd shuffled cars around the driveway several times recently and I know she runs quite rich at idle. One was a little dark but not too bad, the other though was definitely a little more oily.

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I'm not actually surprised that this one is oilier than the other - the car is always parked the same way on the driveway and it slopes to this side. Any oil that settles in the inlet tract and finds it's way into the crankcase will tend towards that side because of the slope. Being the cylinder nearest the fan I imagine it does run slightly cooler too.

A quick session with the blowtorch got the carbon and oil off the plug. I'll do an test run and try to get her out on a faster road to get things cleared out a bit better soon. I think there is an idle air adjustment on the carb as well which I think could do with opening up a bit.

One further tiny detail on the pinball project has been revived, the coin door illumination.

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Aside from just looking better this also doubles as a useful visual power indicator.

There is no evidence of this coin door ever having been fitted with a chute on the third slot (which is why there are only two lamps), I think the third price plate there has just been stuffed in there to fill the gap by someone at some point in the past, it was held in place by scrunched up bubble wrap when I got the machine.

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So I'll be removing the odd one out there and replacing it with a proper blanking plate as would originally have been fitted. Like so.

I randomly stumbled across a pair of nice stainless steel buttons while looking for something else which will also be getting added to the coin door soon to act as our start and add credit controls.

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These will be positioned with the start button on the right of the coin slots (this is actually where the start button was as standard on this table) and I'll be putting the credit button where the coin reject button used to be on the left. The stainless steel should look pretty inconspicuous against the chromed bezel they'll be sitting in.

A little cardboard aided design has helped give a better idea of how things should look when there aren't gaping holes in the machine.

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Having the glass in place will make a massive difference as well but I'm not even thinking about getting that yet as I don't want to have to manhandle a 21 by 42" sheet of glass (or find somewhere to put it) any more often than I have to - so waiting until everything else is done I think makes the most sense.

-- -- --

[] 22nd July.

We now have more buttons. Add credit on the left (used to be coin reject), and start game on the right (where it used to be).

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I reckon that blends in pretty well and you'd never notice unless you actually knew the arrangement that would have been there on a Bally coin door of this era. Random photo from the internet to show the original setup.

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Yes, I will be replacing the missing decal in due course (the graphic will be slightly different as that's a slightly later machine than mine).

-- -- --

[] 25th July.

We've had my mother in law visiting for the last week or so which is why I've been quiet as that's eaten up quite a bit of time.

Spent half an hour or so this evening working on the pinball table.

The coin door lights you may have noted while working were dimmer than expected. Yes, that would be because I had them hooked up to 5V rather than 12V because I was rushing. They look rather happier wired up properly.

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A "quick and easy" job I figured was installing the intake fans. I thought this would be a ten minute job as it was just a case of grabbing the 120mm hole saw, cutting two holes, screwing the fans in place and hooking them up to our 12V line (using the feed to the coin door lamps as it's convenient).

Ignore the mess of wiring at the moment - this is deliberately all being done loosely at the moment as a whole job is neatly routing and looming the wiring at a later date. I'm expecting to have to alter things a bunch though so there's little point worrying about that at this stage.

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"It'll be easy to cut the holes, the cabinet base is pretty thin ply."

Yes it is. Except for one small area - right below where the cash box sits - where there's a fairly thick metal plate. Two guesses where I decided to put the fans.

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My hole saw did NOT enjoy cutting that. However I'd already cut through the ply when I discovered the plate so I was committed to it by then so just pushed through it. I'll obviously need to protect the edges of that as they're quite sharp. Will probably just move the intake grills to the outside.

The location was chosen specifically to try to force some airflow through the area where the display sits as well as through the cabinet itself. I've established that the cabinet actually breathes surprisingly well just due to convection, but we're now also pulling in a good amount of fresh air at the lowest point. We'll need to do some soak testing and monitoring to ensure that everything stays at a sensible temperature once we've got the glass in place on both the main and backglass displays.

The smaller hole you can see right towards the right of the frame is where the factory power switch was originally fitted - that's where the power button which wakes up the whole unit will be fitted once that arrives. I've got a big 40mm button on the way for that.

We do need to add a few more buttons to the machine. We need...

[] Left/right flippers. Originals re-used.
[] Start game. Original location used.
[] Add credit. Coin reject location used. That's where we currently are. We still need...

[] Exit game/menu back.
[] Left/right magnasave.
[] Launch ball.

The Magnasave ones are easy enough - those will just be added using the same style of buttons as the flippers, exactly as they were on most machines which had this functionality. They were usually fitted horizontally behind the flipper buttons, but that's not really practical without modifying the side rails. We'd also run into a conflict with space for the display.

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So I'll be fitting them immediately below the flipper buttons.

It's not needed on all that many machines (Black Knight is the only one I can immediately think of off the top of my head), but we don't really want to half do this - and they're also used for configuration page scrolling and skipping whole letters/category in the table select software. I've already got the necessary buttons on the way for this, I just need to be careful to get them fitted straight.

Quite a few of the later games (Medieval Madness, Attack from Mars, Jurassic Park, Terminator 2 I can immediately think of off the top of my head) don't have a conventional plunger, instead using button and launching the ball using a solenoid. Crop of a photo of a random Medieval Madness table to demonstrate.

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A pretty "standard" way to handle this on virtual machines is to install a launch ball button right below the plunger. That doesn't look too bad on a modern looking cabinet, but I think with is trying to maintain the more period look of this one will look a bit odd. The software should actually be clever enough to allow the plunger to do this by interpreting the plunger being pushed beyond it's home position by pressing against the spring as the same as a ball launch button being pressed. If that behaves consistently I'm inclined to stick with that.

Final one we need is a way to exit a table when we're done playing it or to open the menu in the table selection software. I'm inclined to use a button the same as the ones used for the start/add credit buttons. Though need to decide where to put it. I'm leaning towards symmetrically opposite where the plunger is as symmetry just makes sense to me. Open to suggestions on that though.

-- -- --

[] 27 July.

Small but important component turned up today, which will make it waaaaay easier for me when it comes to keeping the spaghetti under control in the cabinet.

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These will be forming our bus bars for each of the respective power rails. Helpfully they're numbered as well so I'll be able to populate a list of what's being hooked up to where as we go and allow me to draw up a full working diagram when we're done, which will make any future diagnostics or the like far easier.

Also going to be helping my sanity by being consistent with the wiring. For a start power and signal will be kept separate - even if they're routed together they will be loomed separately. Colours will be consistent as well.

DC 5V = Red.
DC 12V = Yellow.
DC 24V = Blue.
DC Common = Black.
Ground bonding= Green.
Signals = White.

I'd originally planned 24V to be orange (to ensure we're not using anything which could on any planet be confused with mains), but I don't have that in stock, but I've plenty of blue...so blue it will be. Realistically mains confusion isn't going to be an issue as all the mains is going to be in one far corner of the cabinet as the only things which will use mains will be the backglass and playfield monitors and the power supplies themselves. The DMD monitor is 12V so I'll just be tying that into the main DC bus as that in one swoop gets rid of a power brick I need to find space for. A bit of appropriate labelling can help with safety as well.

Did I remember to order wire terminals to go with those terminal blocks? Um...that would be a no. Oops.

-- -- --

[] 29th July.

Volvo actually got a bit of attention today.

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Nothing amiss, just time to rotate the tyres. I'm too lazy to do it myself when it takes these guys minutes. I also had one of the tyres swapped onto another wheel that was passed my way by the previous owner as one had a pretty good buckle in it. Turned out that once it was balanced you couldn't feel it at all but it made sense to get it swapped over while I was here.

A box of pinball bits turned up this morning.

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Bunch of buttons - several of which I don't actually need, but it was cheaper to buy a set than the ones I wanted. Several general purpose buttons (the legends can easily be changed), a WPC style ball launch button, two flipper buttons and switches, and a service panel.

The slightly larger red button was intended to be my main power control. It wanted to go in here where the original power switch was.

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The hole there being slightly larger than the switch meant of course that we needed something to attach it to. I'd planned ahead for this and kept an offcut from another recent project and had a perfectly sized chunk of wood on hand for this.

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One switch mounting panel.

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Installed.

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Which is accessible through the cutout in the underside of the cabinet. Nice and easy to get to.

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That's just hooked up to the power switch line to the PC motherboard.

I'd had a think further about the ball launch arrangement for tables set up for a button based launch. It is possible to set it up to have the plunger provide this functionality by pushing it in beyond the home position. Though this always going to be a bit clunky. Not an issue for a lot of tables, but some do require precise timing for a skill shot on the ball launch so a button really is going to work better. So I'm going to go with that. You also want a fairly lightly weighted clicky button rather than the ones I've used for credit/start which have too heavy a draw on them.

I was wondering where exactly to put it when I noticed something.

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Aside from what appeared to be a single woodworm hole - I noticed that when I got it and it does appear to be the only one - see that circle just below the plunger? That's a plug. I assume used by the factory to allow for different plunger setups. Seems a good starting point.

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It wouldn't be possible to use the WPC style ball launch button here as it would foul on the plunger housing.

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Honestly I didn't fancy using that button anyway - it's just too big it feels like to me and looks out of place on this age of cabinet.

One of the smaller (20mm?) ones though feels like it's more in keeping scale wise.

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I'll change the legend to ball launch in due course.

I decided to add the exit button lined up with that one. I was hovering between having the table more symmetrical from side to side, but decided to stick with keeping everything on one side, which I think will be tidier.

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That was a pretty easy one to decide on, but the additional flipper buttons needed some more thought. These are generally referred to as Magnasave buttons as that's the most common feature they were generally used for, and it's just easier to type than auxiliary flipper control.

Ergonomics I decided were a good guide for this.

This is roughly where your hands tend to sit when playing the game.

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After a bit of pondering I went for this.

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Which I think because I stuck with a position in a straight line between the standard flipper button location and the top of the table leg, looks tidy enough. Yes, the new button being stark white does stand out a bit compared to the one above it with 44 years of yellowing on...but there's only so much I can do! I don't think it would really be noticeable at a glance, especially once I've dismantled and cleaned the originals.

I then made a godawful mess and got all the toys out the toolbox.

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I decided that we were probably far enough in now that it made sense to start dealing with some of the spaghetti we had generated. While there are some things which are still subject to change, most of what's in here now is largely unlikely to be going anywhere. So I basically ripped every single low voltage wire out of the cabinet save for the wires to the flippers.

First thing to go in was the first few of our DC bus bars.

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Having those was the main incentive to do this now, and why I hadn't really bothered with it previously while we still had a bunch of Wago connectors tying the DC bus together.

Obviously this is all just loosely in place at the moment routed through the guides (yes those are 15mm pipe clamps), strategic zip ties and such will eventually be employed. Oh and yes I will be adding protection to the section that flexes by the coin door hinges - there are a bunch more wires to be added there yet though (coin switches - yes I'm making those work too, slam tilt switch, all the buttons for the service panel) so it's being left as is for now.

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One change I'm making tomorrow is using one of the busbars to make up a common star point for the signal side of things as the common terminal on the controller is getting...congested.

Mains side rat's nest hasn't been touched yet.

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That's probably next up. Just shortening a lot of the cables will help a lot. That beige box and its wiring can disappear too as I'm just going to hook the centre monitor up to the 12V bus as it just runs on 12V - the backglass and playfield monitors on the other hand have internal PSUs so need a mains supply. I may actually swap that extension lead out for a mini consumer unit as I like the idea of keeping the mains side of things as separated and out of reach as possible and that allows me to easily add both RCD protection and appropriate fusing for each circuit without the bulk of half a dozen plugs stuffed in the back of the cabinet.

I was only slightly apprehensive about plugging it back in given the amount of things I'd disturbed - but it just worked.

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Even better all the new controls I had just added also worked.

Feels like that's some decent progress today.

-- -- --

30 July.

A couple of weeks ago the Trabant decided to be really grumpy, misfiring badly under load. I was pretty sure given the car had been shuffled around on the drive several times and had been left idling for quite a while. I know she runs a bit on the rich side at idle, and suspected we just had a fouled plug. Given this is a two stroke, fouled plugs can just be a thing - first time I've run into it so far.

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Yep, that would do it. Hard to see in the photo but it was pretty oily. Quick session with the blowtorch got rid of it. Finally got a chance to take her out for a run today on my errands, and the miss does indeed seem to be gone.

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I'll keep an eye on it. I know she could do with being a little leaner at idle, but seems to spot on under load, and given how dangerous a lean condition can be for a two stroke I'm leaning towards just leaving it be unless this becomes a regular problem.

Did a very brief bit of further pinball tinkering today.

As mentioned yesterday, congestion around the signal common terminal was starting to become an issue as we had I think six wires all crammed into the one terminal.

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Yeah. That's not going to work. It was okay for brief testing, but beyond that no.

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Much better. That busbar will be used entirely for the input signal ground.

This spaghetti originally providing power to the DMD monitor was evicted.

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That has now just been hooked up to the 12V bus.

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Had a quick look at one of the to do list items for the Rover - investigating the cut cable between the two bits of the radio. Have to roll my eyes that someone chopped the cable when if they had removed one screw the connector just unplugs at this end.

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I was hoping it might be socketed at the other end as well as this would have made the repair easier. Sadly not.

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Guess I'll be repairing that when I have the chassis out of that enclosure as it'll be a right faff trying to repair it that close to the enclosure - just shortening the cable by a few inches and soldering it back in that way I think will be easier. It should be more than long enough I think. That's going to be a job for another day though. Likewise evicting all those waxed paper capacitors.

-- -- --

Found something I wasn't looking for when digging around in the boot of the Renault today, a bag of P4 bits which evidently I missed when loading the last one up. Not much useful in there...except for this.

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Which is helpfully the exact bit of trim I'm missing.

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Just wedged in place there, but you get the idea.

-- -- --

While the low voltage side of things in the pinball table has been somewhat tamed the mains side was still a bit of a disaster of spaghetti.

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Oh yeah, it was also all dangling of that trio of Wago connectors. It was only ever intended to get us up and running for testing though which it did just fine.

This needed a bit of tidying.

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This made for a reasonably satisfying before and after after a couple of hours of tinkering.

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Yes I know an actual consumer unit is overkill for mains distribution here, but equally it seemed a better solution than anything else I could come up with. It also gives me a nice way to be able to isolate given bits of the system easily, and also provided a convenient place to put the contactor as the ones I've got are DIN rail mounted.

It's a bit bulky and heavy...but they're really not things I'm worried about in this application - especially tucked away in that back corner.

I do need to check if it's mounted slightly off level like it looks in the one photo, as that will drive me mad!

-- -- --

31 July.

Very quick additional tinkering on the table this evening.

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Note the two grey devices at around 4 and 8 o'clock. They're contractors - cheap contactors. These are connected up to the interface board and are being triggered correctly by the Direct Output Framework software, acting as stand ins for what will eventually be replaced with something more akin to actual pinball machine flipper coils and mechanisms. So it does indeed now physically go "clunk" when the flippers on screen move. It's not essential, but will very much make it feel like you're playing an actual table rather than a simulation which is the whole idea.

Using these cheap contactors to initially get the software set up and get the basic concept working because they're a couple of quid each rather than £40 or so apiece. They will probably do fine actually for the lower power coils like the slingshots, but the flippers and pop bumpers really need something a bit meatier. Which makes sense given that those coils are more akin to the start solenoid on a car - designed for short duty cycle use only and pulling at least a couple of hundred watts.

Most reasonably modern (read: this side of the 70s) flipper coils are actually wound in two halves - one with very heavy windings and one far finer. The end-of-stroke switch is used to switch between a series and parallel arrangement, so you can get away with a far beefier coil (therefore a stronger flipper) but without risking it burning up the coil if you hold the flipper button down for more than a couple of seconds. While most the innards of a machine will run on 12/24V (and of course various logic levels for the digital side of things) the flippers are usually ~50V. We're probably just going to stick with 12 or 24V here though for the sake of simplicity - and because we're not needing to actually fling a heavy metal ball around a table so can get away with some compromises.

-- -- --

3rd August.

Something I forgot to mention previously about the contactors - and indeed any wound components like motors or even smaller relays - was that if they don't have them incorporated, you really need to add commutation diodes to deal with the back EMF generated when the power is cut to the coil.

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Shown there before heat shrink was added obviously.

Even a little 12V coil like this can easily generate a spike of a couple of hundred volts into an open circuit as the magnetic field collapses, and given we have sensitive electronics (like a PC motherboard) on the same power supply here that could be bad (and expensive) news.

I do also have diodes hooked up over on the bus bars as well as belt and braces, but there's no harm in having protection locally.

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The actual amount of energy involved here isn't huge so just bog standard 1N4007 diodes are perfectly adequate.

Good thing they don't need to be anything special given we'll have ten solenoids for playfield devices, plus a replay knocker, three on a set of chimes, two on bells and probably a small geared motor.

A pretty tedious part of this process has now begun: Going through each of the virtual tables and setting them up. Not in terms of the emulation, no. Actually going into the real operator settings which would have been set up in an arcade. It's fairly intuitive on Williams/Bally/Midway machines from the early 90s onwards, and the more recent Stern tables also have a pretty easy to follow service menu - but some of the earlier ones are a right faff. Especially Gottlieb/Premier where it's all cryptic option and variables represented purely by numbers - and where operator manuals aren't usually readily available as they still protect their IP. You can get the manuals, but at $20 apiece for something I purely need the operator setup instructions and pricing table would get expensive quickly with probably 40 or so tables in question...on the plus side, most options that are relevant here carry over between tables built on the same platform so once you've figured out that option 4001-03 needs to be set to 05 on that table to enable free play, it's a decent bet it will be the same for anything based around the same MPU. At least most of the time.

Yes, I am keeping a cheat sheet so if I need to do this again it's less of a pain!

Speaking of service options, a location has been chosen for the button panel for that.

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Get that wired in soon and that will hopefully mean we can pretty much ditch the keyboard entirely.

Continued...
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Zelandeth
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Re: Zel's Eclectic Fleet Blog (Volvo, Rover, Trabant, Invacar & Occasional Distractions)

#1667 Post by Zelandeth »

...Continued from previous post.

[] 3rd August.

The service menu controls have now been hooked up.

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The little red button on the right is actually the self test button from the original cabinet. It is now doing duty as a control which toggles whether the coin door appears open to the emulation. This is needed to get into the menus on a lot of machines - actually implementing a door switch on here would be a bit fiddly as there's no provision for one, and honestly being able to just choose whether it's open or closed is easier as it saves having to keep opening and closing the door if you're testing things. Gave me a good opportunity to let a bit of the original hardware keep being used usefully.

As this isn't a component that's likely to be changed as we move on I decided that we could go ahead and add loom wrap to the wiring immediately by these controls. Given the little compartment to the left there is being used as "misc stuff storage" and likely always will be giving that bit of wiring some protection seemed wise.

While I was in the area I hooked up the slam tilt switch on the coin door and also tidied up the wiring on there.

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I wanted to get that done sooner than later as I felt things were quite vulnerable to getting pinched in the hinge - something that's now impossible. As it's the first thing you see when opening it up, having that look reasonably tidy helps with the first impression I think.

Nice to be at a stage where I feel I can actually do some basic tidying of some bits that I feel are basically finished. We won't be wrapping ALL of the wiring by any means, but i imagine a fair chunk of it will end up that way just because it looks so much tidier.

I don't have any photos, but the last thing I was working on today was testing out a better arrangement for table audio. Up until now we had just been using the onboard speakers in the playfield display, which are predictably very average. They're actually pretty clear and don't distort horribly or anything, but they don't really have any "punch" to them and it all just sounds a bit flat.

The original speaker was long gone, but a random 5x7" automotive speaker I had laying around fit reasonably well over the original cutout, and using a cheap little Amazon Special audio amp has given us faaaaar punchier sound. Much more in keeping with what you would expect from something like this. Given that this was absolutely not hifi sound from new going out of my way to fit a better speaker for that really would just be overkill. Unless this one turns out to be buzzy or distorts horribly (I've only tested it as far as proving it works so far) I'll probably just leave the one that's in there.

There WILL be some quite specialised audio equipment fitted far later on, but that's for more feedback purposes rather than game audio. What will be getting installed will be a set of four exciters which couple sound directly into the sides of the cabinet. What for? I hear you ask. To simulate one very specific effect - the sound of the ball itself rolling around the playfield. I wouldn't have thought of that, but apparently it works very well and does vastly improve the immersion.

Plunger is the last major component we need, and according to Royal Mail it is finally actually in the country after being stuck in customs for what has felt like about a month and a half. Once that's fitted I can get a proper enclosure made up for the apron rather than the current random bit of cardboard.

-- -- --

4th August.

Small details are continuing to be the order of the day.

The PC's SSD has now been properly secured in a caddy rather than just being wedged in place. It doesn't run warm really anyway but I've positioned it such that the intake to the CPU cooler will cause a bit of airflow over the drive during normal operation to help keep it cool.

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Given their location, it only seemed to be a matter of time before I either dropped something into the fans, got my knuckles skinned by them or had a wire chewed up by them so added some protective grills inside the cabinet as well as outside.

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That just seemed a sensible thing to do before we ended up with blood being spilled. There has already been a blood sacrifice on a couple of occasions, so let's not leave unnecessarily opportunities for more!

Actually played a couple of games this evening and can confirm that this little audio amplifier and the separate speaker in the cabinet base has made a big difference.

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I do need to tweak things a little though as it's picking up quite a bit of interference on the audio feed to the amp - I know it's noise on there as moving the input cable around makes it change. I might see if using a shielded cable solves it, or if a bit of careful routing helps. I'm pretty sure the graphics card on the PC is where the noise is actually coming from.

Here's a comparison between the machine itself and a game on my phone which I used to play quite often. Same table, different platform.

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The screen I'm using now is just a *little* bit bigger...

-- -- --

7th August.

Last major component I'd been waiting on turned up today.

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This is the bit of kit to make an exceptionally analogue device - the ball launch plunger on a pinball table - translate into a digital simulation.

Helpfully the I/O board already has a dedicated set of terminals on the input side set aside for the plunger, and even has the terminals labelled.

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The wiring even came labelled ready to install.

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They weren't wrinkled up like that when it arrived, that's after being dragged through one of the cable management eyelets.

It probably won't surprise those of you who have followed this project from the start that we had clearance issues. In this case with the ball launch button - so I had to trim the surround a bit.

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Not a problem though, the lower mounting bolt isn't used on this type of plunger anyway (this kit is designed to work with pretty much all the mainstream types) and there's plenty of surface area to securely fasten in place. Ideally I would have installed this *before* the buttons so wouldn't have had this issue, but hindsight is always 20/20. Honestly the button position works well from an ergonomic standpoint so an extra five minutes installing the plunger isn't a big issue.

Here's the end result.

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Once again in a huge shout out to the designer of the software that drives this lot, it Just Worked. All I had to do was select the potentiometer option in a drop down list for the plunger type and click a big very clearly labelled button to calibrate it. Said calibration took about 15 seconds and just required me to operate it normally several times. It now works exactly as you would expect it to if you were launching the ball with a manual plunger on a physical table.

This is essential for it to feel real if I'm honest. If you're someone who has played any amount of pinball, pulling back and releasing the plunger is one of those very well ingrained muscle memory type things which is just linked to the game.

It's also important for the gameplay in some cases. Several games have a skill shot where you can score (in some cases quite sizeable) bonuses by shooting either a target on the playfield, which is done by carefully modulating how hard the ball is launched. Examples I can think of off the top of my head are Bride of Pin-Bot, Taxi, Tales of the Arabian Nights, Ripley's Believe it or Not are ones which spring to mind - or even Four Million BC which implemented that (and three ball multiball AND Zipper Flippers) on an electromechanical game - that's a fascinating game almost worth a rambling post in its own right, Ted Zale at his very best. Others either have you time the launch to coincide with a specific event (Medusa, Last Action Hero, Jurassic Park plus probably many others) or to predict where a ball will go by cycling a light on the playfield controller by the flippers (Medieval Madness, Attack from Mars and many others). The latter two setups work fine with a button, but anything requiring you to modulate power is near impossible with a button. Functionality aside though, it just feels better!

We are now up to eight contactors in the bottom of the cabinet to make physical clunky noises and feedback to coincide with things happening on the playfield. This will eventually be ten when the two far more powerful coils for the flippers arrive (at which point I'll relocate the two currently serving that role will move to the back corners).

In the same package as those coils there is also an LED flasher light bar and an expansion board for the I/O controller which will give me an extra 21 outputs to play with - which is needed as I'm down to two left now! Those two will be full once the last two main coils are fitted - but I'll still be wanting another five for chimes and bells, the replay knocker, plus the light bar which will need FIFTEEN just in its own (five RGB LEDs and each of the colours is independently addressable). That might seem like a lot of effort for some blinky lights, but it's actually something which will add a bit of visual drama that you just can't get from a video display. Those will likely get fitted to the currently white bit of trim immediately above the main display.

Speaking of lights, here's a look at the playfield lighting on Bride of Pin-Bot. You really could be forgiven for not immediately realising that this is a computer simulation...never mind a photo of a video screen showing a computer simulation.

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I shudder to think how long that must have taken to model. Let's not forget this is something that someone has made and is distributing completely for free rather than some huge game design studio.

Here's what you currently see immediately behind the coin door on the table.

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Immediately to the left you can see how readily accessible the service control panel is. You can also see the very deliberate space below the main display. This is there to ensure that a decent chunk of the air from those fans is diverted through there and helps keep the display cool.

Someone asked me how on earth I keep track of where all the wires are going, and the answer is that so long as I know what type of wire it is, I don't need to. This is the magic of having a controller running the show with is essentially software defined. So long as I know that the inputs are connected between the input common and AN input port, that's all I need to know physically. Then I simply go to the input test control panel and see which port changes state when I push the relevant button. I then tell the control program what I want that input to be mapped to. Outputs are handled exactly the same way. I just make sure they're correctly connected to the respective power rails and their ground side goes to an output port. Then I toggle each output in the software and see what operates, then tell the software what's connected to that port. Obviously I have been writing a road map as I've been going as I will want that information if I ever need to find faults, but at the initial build stage the ability to make any input/output port be allocated to any function is an absolute godsend in terms of helping simplify things.

-- -- --

17th August.

Back from a nice trip away in Aberdeenshire last week. Definitely needed that.

The Volvo unsurprisingly dispatched ~1000 miles of driving without any difficulty, returning mid 40s MPG throughout the trip. Though it does now need a wash.

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A bit big on some back roads but that car is unbelievably good at dispatching long distances in the blink of an eye.

Mostly been catching up on everything that stacked up while I was away, but found time to do a bit more work on the pinball table today.

The flipper buttons needed some attention. Particularly the right one would occasionally bind a little, especially if pushed off centre. My hunch was that this was due to god only knows how many years of grime. Certainly looked that way when I pulled them apart.

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Looked a lot better after a good clean.

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Back in place.

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This seems to have resolved the binding issue. Time will tell I guess. If not I'll swap the buttons out for a new pair - they're not expensive.

Probably the biggest visible change in a while was made today with the construction of this.

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Which is a cover for the gap between the lockdown bar and the bottom of the playfield display - essentially where the apron would normally be on a real table.

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Obviously paint will happen in the near future.

I did run into one issue though in that there wasn't *quite* enough clearance, so the tip of the plunger would just touch it when released - producing an extremely loud bang. Solution for this was pretty simple - cut a hole in it. A rubber bung will go here shortly to cover the hole while retaining the clearance.

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Get some paint on there tomorrow.

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Will also add some instructions there on how to use the machine - will break up the space a bit more so it's less obviously not what would normally be there - which would normally look something like this.

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Challenge will be figuring out how to make it look in keeping with the original table art.

-- -- --

There we go, a bit of paint has made that look a bit less scruffy.

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Next step will be to make some labels with guidance on how the machine works. Will obviously be heavily based on the apron artwork from Eight Ball Deluxe (and indeed most Bally tables from that era).

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Pretty simple really. I've got a decently high resolution copy of the Bally logo I believe and a note of the typefaces that were used, the rest should be easy to put together in Gimp. I just need to decide exactly what information I want to put on there.

-- -- --

19th August.

The central display for the DMD worked but had an issue with the fact that it was just too dim. It could just about be passable for direct viewing but was far too dim once the red filter was added. In fairness, I think the panel cost something like £30 so I'm not going to lose any sleep over it. It's still handy for random testing of computers which is mainly what it's been used for before.

Today a more permanent solution arrived. A little 12" ultra wide industrial panel. This is more intended for point of sale advertising displays or other industrial applications and as such is stupidly bright, even just at the default settings. If you turn the brightness up it's honestly painful to look at.

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Those are all showing the same light grey.

This does a much better job of still looking properly punchy even once the filter is back in place.

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Obviously it will be positioned centrally in there in due course - it's just wedged in place on a bit of cardboard in these photos. Being an industrial panel it's in a metal case with several mounting options so shouldn't be difficult to get it mounted securely.

I also seem to have finally got to grips with how the point of view options interact and have pretty much got things set up so the proportions look correct from where you stand in front of the table.

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Now I just need to go and tweak those settings...on each of the currently installed tables. Which to date number 138. Only takes a minute or two to set each one up, but it quickly gets tedious!

I do really need to do something about shielding the input to the audio amp as the squealing it picks up at some points (particularly in the menu rather than when a table is playing) while it's really pretty quiet is really bugging me.

I'm really looking forward to actually just getting a few hours in just playing this thing at some point! Nevertheless, it is quite satisfying looking back at some of the earlier photos and my scribbled ideas in a notepad to see how far it's come from the original idea I had a year or so back.

Once we're near enough finished I will probably add up roughly what it's cost me and see how it's compared to just buying a commercial virtual cabinet. A few folks have asked if I could build and sell something like this - and that's a pretty firm "no" in my mind. Not even taking account of the hours I've put into it and keeping in mind that quite a lot of the big ticket items were bought secondhand (main display, CPU, GPU, cabinet) or were just random electronic supplies I had in stock, it's still going to be pretty well into four figures. I'm a little apprehensive about how much the glass is going to cost as I've really no idea what to expect there. Assuming I can even find anywhere locally that will cut a couple of panels for me. That *sounds* like a simple enough thing, but I've learned not to make assumptions like that any more.

While I may complain that the graphics setup is tedious, the really tedious bit is still ahead of me and that's going to be getting the cabinet tidied up a bit. It's not being fully restored and repainted, I don't mind it showing that it's got some miles on it, the thing is 44 years old. I do want to tidy it up a bit though so it doesn't look *quite* so like it's just been abandoned for a decade or two then dragged out the back of someone's garage. Which it was! Paint is something that you can't rush. It'll be a faff to match the colours as it is given how much it's faded (and that varies especially on the one side which has obviously seen the sun) even before I try to strike that awkward balance between reasonable repairs and overzealous restoration.

-- -- --

23rd August.


Two far more chunky solenoids for the flippers have also arrived though I've not had time to connect that up yet. The two currently serving that role will be relocated to the back corners to give us a full 3 x 3 matrix to allow correctly localised feedback for things on the playfield.
[/quote]

-- -- --

26th August.

The weekend itself was a bit of a change of pace. Something I randomly stumbled across a couple of months ago was the fact that there is actually an annual pinball convention in the UK. I think it was in the news section on VP Universe. This was something of a surprise for me as I didn't figure it really had much of a following over here. I was even more surprised to find that it was only half an hour up the road in Daventry. So of course I signed up to go and investigate.

Let's just say that I had sliiiiiiiiightly underestimated how well attended the event was going to be.

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There were a bunch of tournaments running over the course of the weekend, though I was really just interested in the 100+ machines they had set up on free play.

So what did I spend the most time on?

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Jet Spin. Has been a favourite ever since I got it running on my virtual setup at home. Simple table in terms of the rule set but it's just enjoyable to play.

A close second was one I'd never really given much time to before, Jungle Queen.

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Again pretty simple formula but enjoyable. Plus once you've got the hang of it even I can pretty consistently run out of score reels.

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Quite satisfyingly I found that my average scores on there were actually very close to what I've been seeing on my cabinet at home (well that's Jungle Princess - but it's just the two player version of exactly the same game) which suggests to me that my setup is probably reasonably true to form in how it behaves.

It's probably a good thing that I respect the fact that I have no room or this probably would have come home with me.

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While it's a little care worn and needed a bit of a service (and the LED conversion undone, sorry I just don't like it on classic tables), £1200 for a proper Steve Ritchie designed table to me in the UK market sounds really cheap. If I had the room it would have been in the car on the way home with me.

A bit of a neat spot during the weekend was an Eight Ball Deluxe LE - what my cabinet used to be.

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Though my biggest surprise of the weekend was this madness - Orbitor 1 by Stern. Yes spelled like that, someone had trademarked the proper spelling apparently!

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This thing looks wacky, but how it plays is orders of magnitude weirder than you'd imagine possible. For a start, the playfield isn't flat. It's a fairly gently contoured valley, which obviously has an impact on how the ball rolls. That's only half of it though - I initially thought there were magnets or something under the playfield as well as the way the ball behaved just defied any other explanation. However it's way simpler than that - and really clever. Those two red bumpers in the playfield which look like pop bumpers, they're actually spinning and covered in a pretty grippy rubber material. So in addition to bouncing the ball around they also impart ridiculous amounts of spin to it. This results in some incredibly odd looking behaviour.

Jump to 02:00 in the video below to see what I mean.

https://youtu.be/FvUweFvxqWc?si=-Syp8MNsLF5Kp-1-

My initial reaction was basically standing there with a comic strip thought bubble reading "...?" above my head after I launched the first ball.

It's a fascinating table and a huge amount of fun to play. Definitely one that's on my "Yep, I'd buy one if I had the room" list now. Also notable as being Stern's last table before they exited the pinball market until they reappeared in 1999.

This was quite a neat idea someone had done to make a display piece of this Nautilus. It's always a bit of a shame that so much of an EM table is hidden away never to be seen - this shows off all of those dozens and dozens of relays.

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All in all it was a good fun weekend. I'm nowhere near skilled enough to be a worthy competitor in any of the tournaments, I was just there to enjoy playing some pinball. Was also quite useful for me being able to snap photos of a bunch of tables from my usual standing position for fine tuning the field of view settings on my cabinet. Will definitely be going back next year.

Did have a bit of excitement i could have done with on the way home though. Driving along quite happily when out of nowhere the car developed the worst vibration I have ever encountered in a vehicle. I thought the gearbox, a CV joint, collapsed engine mount or something like that had let go. It was honestly violent enough I was worried about it triggering airbags and things like that.

A bit of investigation once I pulled into a side road (of course I was somewhere I initially couldn't stop safely) pretty quickly found the culprit.

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Yep. That's dead! No chance the can of goo most cars seem to come with nowadays would have been any use. It's a space saver, but at least the Volvo does have an actual spare wheel. Ten minutes and we were back on the road.

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Were it not for that I'd probably have been sitting there two hours plus waiting for recovery to turn up.

Honestly between how heavy a car it is, how unnecessarily hard the suspension is, the daft low profile tyres and the horrific state of the roads around here, I'm surprised I've only had one blow out so far. What does worry me though is how much without any warning this let go though. They were last checked on Friday afternoon and the pressure was spot on then, I certainly wasn't aware of any signs that we had lost pressure leading up to the event. Just suddenly the entire universe was trying to vibrate itself apart around me.

Having one odd tyre on the car as I'll have to have now is going to bug me something rotten!

No real harm done though, and it didn't take the shine off what had otherwise been a good weekend for me.

-- -- --

28th August.

First up I want to issue an apology. My phone upgraded itself to the latest version of Android a few days ago and one of the very obvious changes is that autocorrect has become FAR more aggressive. However it also seems to have at the same time become far more erratic and is often autocorrecting things with utter nonsense. I do try to proof read things before hitting submit, but I'm not the best at spotting where nonsense like that has happened.

Using an external keyboard doesn't even stop it!

-- -- --

Very quick upgrade made to the pinball project today - far beefier coils for the flipper feedback devices. The little contactors I'd originally used (because they were readily available and very cheap) just didn't give anywhere near as substantial a thunk particularly for the flippers. These should be more what the doctor ordered.

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These are actually made specifically for this application. I may well upgrade a couple of the others down the line, especially for the centre rear playfield which does most of the work simulating the pop bumpers, but will probably go with something more cheaply available like a generic automotive starter solenoid for that. Having some variety between the various items isn't a bad thing anyway as there is in a real machine too.

The light bar behind the display is also now working. This helps make up for the lack of brightness from display panels just not being able to produce the same effect as the high intensity flash lamps which there are on many tables.

These five lamps are all addressable RGB units which are handled by the Direct Output Framework and operate in time with events on the tables - either when the flashers would be fired there, but also just where the folks doing the digital conversion felt it was appropriate. They have some decent punch to them.

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The centre display is also far brighter now it has the new panel in place - I just need to paint the backing board for it so that's not visible through the window.

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Once that's done the score displays should just "float" there without the display itself really being obvious.

Was quite nice yesterday evening just playing the thing for an hour or so as I'd intended. We're definitely down to more of the detailed work now.

-- -- --

31st August.

This afternoon I had a patient in need of some help on my operating table.

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Given that virtually all my Amiga time has been on the A1200, I always forget how tiny the A600 is in comparison.

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This one doesn't belong to me. It belongs to a friend who isn't all that familiar with the platform, and was reported to not be reading disks. It wasn't even *trying* to read them though which is a big clue.

Amigas of this era have a disk presence switch so unlike on a PC, as soon as a disk is inserted the system will spin the drive up and try to mount the volume (and start booting from it if it's a bootable disk) without any user input. My guess was that this was where our problem lay as it wasn't doing anything.

Missing screws and scratch marks suggested I wasn't the first one in here, and that the problem with this drive most likely was why this machine was "parked" however many years ago it was.

A close look at the floppy drive revealed my hunch to be correct. There was a dry joint on one of the disk presence switch terminals and it had come away.

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Thankfully I was just about able to sneak the smallest tip of my iron in there to solder it back in without having to take the board out - as that would have meant pretty much completely dismantling the drive, which is never high on my list of favourite activities.

Back together and sure enough, it now attempts to read any disk as soon as it's inserted.

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Of course I can't find any of my physical Amiga disks (I stuck a Gotek in my A1200 a year or so back and have a feeling I put the disks into deep storage) to confirm it's now working properly, but I cleaned the heads while I was in there so there's no reason it shouldn't. We'll test it when I drop it back with the owner (or if I have a brainwave and remember where the box is). For all their reputation for being unreliable, floppy drives (especially older ones) really are surprisingly dependable so long as the heads are kept clean and you're not trying to use mouldy old disks covered in greasy fingerprints. 99% of the problems I have have been down to mould having got to a lot of my older ones at my parents house in the early 00s where they had horrendous damp problems.

Nice to find a nice, simple, easily repairable physical failure for a change!

It's also a small world. This sticker is on the bottom of it.

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Keith is about 25 miles from where I call home up in Aberdeenshire, 400 plus change miles north of where I am now and where this computer has ended up, yet we somehow ended up crossing paths down here in the Midlands.

I did have to sit on my hands not to completely dismantle and clean the thing...but I'm only meant to be fixing what's wrong with it! It's actually a pretty tidy example aside from needing a clean, it's survived without yellowing far better than my A1200.

Said A1200 I need to get back back on the bench at some point to try to figure out why the hell it was behaving so erratically last time I was trying to use it - my money being on a memory problem. That's a job for future me though. This patient though appears to have made a full recovery and is ready to go back to it's owner in the next couple of days.

-- -- --

Did a little bit of pinball tinkering this afternoon as well. While the new solenoids were louder than the old ones, you couldn't really feel them doing anything which is half the reason they're there. I decided moving them onto the side of the cabinet far closer to the flipper buttons was probably a good solution for that.

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Another feedback device has also gone in - a shaker motor. Basically the same idea as what makes your mobile phone vibrate but majorly on steroids.

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This is actually a proper pinball part, and is a kit intended to add the functionality to modern Stern tables where it was an option on several games.

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We obviously didn't need the interface board or anything, just the unit itself, fixings and the safety cover.

This has been slotted in amidships between the audio amp and the interface board.

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This is something which isn't fitted to many older tables (Jurassic Park and Earthshaker are the only older ones I can immediately think of), but as with many things because it's controlled through DOF, it's functionality which had been added to many more at appropriate moments and it does actually add quite a bit of extra drama. I did have to dial it back quite a bit though as it was just far too violent running flat out!

-- -- --

7th September.

Big surprise - the sub £10 audio amplifier went pop this afternoon. Can't say I'm massively surprised. It clearly has absolutely zero filtering on the input based on the fascinating squealing and whistling noises it was picking up depending on what the computer was doing. My guess is this is what's killed it, it's gone into some ultrasonic oscillation which has just gone nuclear and wiped out the output stage. I kind of wish it had done this before I went to the efforts of attempting to shield the audio feed to it (which made zero difference).

Let's try fitting something which actually has any chance of functioning properly!

Can't say I was particularly surprised, I only bought that because I didn't have anything on the shelf which fit the bill (size was the biggest problem - an audio amp that would *work* for the application I could grab out the loft in about 90 seconds).

-- -- --

9th September.

New amplifier turned up this morning. It's about half the size of the last one but weighs probably three times as much. Aside from the lack of strange squeaking noises, the audio quality in general is far better.

I think that means that pretty much everything is now in there. Only items still on the wish list are a set of chimes and bells. Those are relatively self contained though and I've already got a location already in mind and kept clear for them. I decided that on the strength of this it was time to do something about the rat's nest that was the wiring.

This was the view looking towards the rear of the cabinet a week or two ago.

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As of this afternoon, it now looks like this.

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It's definitely nothing close to the absolute artworks of meticulously woven looms you saw in a lot of quality equipment made in the 30s-70s, but I think for something thrown together by some random guy on the street I reckon it's actually decently tidy now.

Even better, testing it afterwards showed that I hadn't even broken anything during all my messing around tidying things up (this involved disconnecting, untangling and shortening quite a number of wires).

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There have been a couple of random improvements made in the last couple of days as well. Just tidying things up really. The first of these was actually securing the power supply which had just been sitting in the back of the cabinet. I reused a couple of angle brackets which I think originally held the score display support frame in place to firmly wedge it in place.

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The centre display looked far better when lit than the previous one I'd been using, but with any real ambient light it didn't look great when unlit as you could clearly see where the screen was.

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This is because the wooden panel the panel is fixed to was light coloured.

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Nothing a bit of matt black spray paint can't fix.

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Much better. Yes you can still see the reflection of the display itself, and if you really look for it you can see the frame, but it's a thousand times better.

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A (not unexpected) problem I had with the PC in there was the fact that it was really struggling to maintain a solid connection to our WiFi network at any usable speed. With the antenna buried inside the cabinet this didn't really surprise me. So I have added an external antenna on the back of the machine where you'll never see it once it's backed up against the wall.

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This actually also helps act as a spacer to prevent it being pushed fully back flush with the wall, as doing that would block the ventilation outlets.

The next things I will be meddling with will be adding some trim along either side of the main display to hide the bezel (particularly on the left where there's a big Philips logo and a bright white power LED), tidying up the monitor mounting in the back box, and getting some glass cut I think. Then just play the thing!

We did have a pretty good session a week or so back where we had a few two player games going. Despite having never played the table in question before, my other half absolutely annihilated me!

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107K to 35K...I call beginners luck!

-- -- --

10th September.

Had to do a bit of car work today. As the new clutch (and release bearing, given it's just a graphite bushing) has now properly bedded in in the Trabant I had ended up with the bite point very close to the floor.

Yep, having about 1/3" of free play at the arm would indeed do that.

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Couple of turns on the adjuster and we're sorted. Five minutes start to finish, including finding the 13mm spanner. Now much better - hadn't realised it was dragging a bit at times before, but it's really obvious now - especially changing into 2nd. Coming up on a thousand miles now since the engine replacement, which I find kind of surprising given the car is almost entirely just used bumbling around locally. It does add up quick.

The glass for the pinball table was ordered today. Actually a lot cheaper than I was expecting, a local place has offered to supply both pieces in the correct toughened glass for £120 all in. Should be here in a week or so.

Does mean I've got to try to get most things I'll want the be messing around under there ticked off though as it'll be a bit of a chore having to manhandle a 43x21" sheet of glass so ideally I'd like that to stay put once it's fitted.

A really obvious thing I needed to address was this being right in front of you to the left of the display.

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There's also a little gap there as the base of the display isn't quite flat.

This looks better now I think.

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You can't really tell, but I've totally changed how the backglass display is secured.

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Rather than faffing around with an actual VESA mount behind it, which was just a giant faff to deal with, it's now just sitting on a shelf with some blocks to secure it. I will probably drop it down a touch further yet. The glass going in here will get a black mask painted at the edges to hide the small gaps at the edges.

That was actually something which took me more brains to work out than I'd expected. The fact that the display is taller than the aperture it has to fit through makes it rather a faff to get it into place. Sorted now though, and no longer sitting on a couple of random capacitors to keep it level.

-- -- --

13th September.

Glass was picked up from City Glass today for the pinball machine. Though I haven't been able to fit it yet as I need to move the machine first. The playfield glass slides in from in front of the table, so I need basically a whole table of room in front of it. Given it's currently tucked away in a corner that's not possible. So I'm going to borrow an extra pair of hands tomorrow and play a bit of a game of life size slide puzzle rearrangement of the Purple Room to try to get it into a better location to use and give me room to get the glass installed.

I will want to add a bit of felt or foam to the location the backglass sits in so it doesn't rattle as the new glass is slightly thinner than the original stuff just because this is a metric rather than imperial size, but that's not the end of the world. Shouldn't be a problem with the playfield itself because it's sitting horizontally.

One very important task I need to do before it goes in though is to also clean the playfield display to within an inch of its life and TRY to ensure it's free of dog hair before the glass goes in. Going to have a bash at getting the graphics for the apron made up as well.

I think then we just actually get to play with the thing as intended. Already have been quite a bit, and working on getting the point of view fine tuned for each table - this is a bit time consuming as every table is different. Of course we're trying to create a 3D looking recreation of something in 2D, so that's going to need to take into account where you're looking at it from, and that's going to vary dependent on the size of your display, height of the table, rake of the playfield, how close you stand to the table and even now tall you are. There's also a bit of a liberty has to be taken with the scaling as we're using a 16:9 aspect ratio display and a typical playfield is actually nearer 18:9. So it's easy to end up with things looking squashed - sometimes you do just have to accept either some cropping (you can usually lose a bit of the apron or back panel without it being too obvious) or some distortion.

As you can see, it looks pretty convincing once you've got it right. Here are a handful of tables as examples.

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Eight Ball Deluxe, Bally, 1984. The same playfield this cabinet originally had in it.

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Firepower, Williams, 1980.

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Flash, Williams, 1978.

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Gorgar, Williams 1979. The first table to feature speech. This one still needs a little tweaking.

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Centaur, Bally, 1981.

Not everything has been quite so lovingly rendered in innate detail, for example Victory here is a bit more basic in the graphics department - but it still plays spot on.

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Victory, Gottlieb, 1987.

It's definitely been a fun project, and is satisfying to see it coming together properly now some of the final touches are being added.

-- -- --

16th September.

That has been a rough couple of days.

It is with great sadness that I have to report that we very suddenly lost one of our dogs, Tesla on Sunday afternoon. He went within the space of 12 hours from his absolutely normal self to being deathly ill with no chance of recovery.

While we weren't entirely unprepared for this given that he wasn't young any more and had had a history of having a few lumps meaning he was always going to be at a high risk of developing cancer, it's still a shock. Having said that, I'd take this any day of the week than a slow decline and loss of quality of life until the inevitable. He was happy and loved right to the end.

Here are the first and last photos I have of him.

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Rest in peace my fluffy toasted marshmallow goofball. You'll be missed.

So apologies to folks if I'm a bit off colour for a while, it's going to take a while for me to settle. Also meant that Sunday was a very, very long day and left me both physically and mentally exhausted, so that alone will take time to recover from.

Here's a little insight into his character.

I randomly decided to toss him the bit of cardboard from under a frozen pizza to lick any fragments of food off and/or enjoy himself shredding. He would never destroy anything unless you specifically told him he could - if you threw it to him though, fair game!

https://youtube.com/shorts/eFkmD1ZFysw? ... AVczhBRfcA

Anything and everything can be a game.

You can very clearly see the battle between the German Shepherd bit trying to calmly work it out and the husky "if in doubt bat madly at it" going on.

-- -- --

18th September.

Trying to remember where I'd got to with the pinball table now. I think the glass has just arrived.

I got this installed as quickly as I really could. Simply because by far the safest place for it to live is actually in the machine.

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Looks a lot more finished with the glazing all in place.

The giant empty space on the apron was quite conspicuous though. Ideally I'd get this painted up to be closer to the original colour, but for the time being I just made up a graphic with some instructions on that was based on the original apron design. I was aiming for it to look like the original instruction cards, but it just looks like I left white boxes for the text! Eh, it was only a version 1.0 and took me all of about half an hour to make. Most of that was spent finding a photo of high enough resolution to use as a reference.

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Or at least the early version...I totally forgot that they used a different colour scheme for the LE version, with black, red and silver rather than cream and gold...not sure why given I SAW ONE in person a few weeks ago.

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So I'll probably redo this based on the later colour scheme - random photo from an ancient Reddit thread.

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Which I think will blend in better. Nevertheless having *something* in that space makes it look more finished.

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Using the black/red colour scheme though will open up more options for me though as I've already got a black base there.

Today's attention was turned to the backglass. The fact that you could see all the edges made it look far too obvious it was just a computer monitor. Hiding those edges needed to happen. Not complicated to do though.

Glass out and the centre area we wanted to use was masked off.

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Then the glass was painted with some black paint.

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Which results in a nice clear black border around the edges, hiding the monitor surround from view.

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I will probably add some foam or similar behind those masked areas just so that you can't look into the cabinet if you're viewing it from a really oblique angle.

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This should help keep a bit of tension on the glass too to help stop it from rattling.

Nice to start getting the little details like this ticked off as they do add up and it's starting to feel more polished and less thrown together now.

-- -- --

24th September.

Finally kicked myself into doing a bit of work on the bits of Rover.

Whoever last had the inlet manifold off, I hate you. Apparently rather than replacing the gasket they just slathered it in what looks like several tubes worth of blue Hylomar and smooshed the lot back together.

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Which explains why I reckon I could have lifted the engine out by the thing given how well it was stuck to the head.

I didn't take note of exactly when I started, but this took a substantial chunk of this afternoon.

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It still needs going over once more but the worst of the gunk is off now at least.

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A side effect of the overused sealant was two of the smaller coolant passages having been totally covered. I'm sure that wasn't helping anything.

Now need to remove the partner to this lot from the head...oh, and the underside of the head. Though at least that's just normal carbon and oily gunk which isn't anywhere near as difficult to shift as this was.

-- -- --

27th September.

I think this lot is now about as clean as it's going to get.

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From when I was in the process of scrubbing the head.

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Head seems perfectly straight as best I can tell with the equipment I have.

All of the coolant passages in both the head and manifold were blasted out with the pressure washer as the manifold in particular was quite full of crap.

There's still some staining around the edges of the combustion chambers but it feels perfectly smooth and uniform, so I think will be fine.

The block was a disgusting, slimy mess.

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Not going to win any prizes, but it looked a lot better after I unloaded a few cans of degreaser at it and then attacked it with the pressure washer.

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I will hose out the block as well - but I'm going to do that right before reassembly as I don't want to leave the inevitable water that gets into the combustion chambers etc just sitting there. So I'd rather be as close to ready to get the engine started up, warmed up and dried out when I do that.

I have a feeling it might not actually be horrible in there - the head (and the manifold in particular) looked far worse than anything I can see of the block. Not impossible they're from a completely different engine of course!

-- -- --

28th September.

Well I'd hoped to get the Rover back together today, didn't quite end up getting that far.  Did make some good progress overall though.

Biggest holdup is that given there are a few areas on the inlet manifold which are pretty pitted, I do want to put a bit of sealant on there to help the gasket out (a *sensible* amount rather than the several tubes worth that went on last time around apparently).  Discovered that my previous tube has turned to a rock at some point in the last year. 

Figured it would be something Halfords would have...nope!  Maybe I can grab antifreeze while I'm there at least.  Not a chance, any modern flavour I like, but not a single bottle of the old blue stuff...Well that was a waste of my time, and some idiot has scraped the passenger side mirror on the Volvo while I was parked.  Great.  I'll go grab both things from elsewhere tomorrow - an hour and a half round trip I could have done without. That'll teach me not to use the Trabant for my short trip.

In better news, with the jammed heater valve removed, turns out we do have perfectly decent flow through the heater core on the Rover.

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Not even all that much gunk came out of it to be honest.

The valve however is a block of aluminium oxide and rust and is utterly beyond saving.  They're not expensive so I've got a new one ordered.  There should have been an O-ring between the two parts of the connection which was completely missing...so I'm guessing it was purely sealed by scale and rust! So maybe didn't get far towards getting the head back on, but I'll take the progress towards a working heater.

I've flushed as much of the gunge out the block as I reasonably can without pulling out the (clearly pretty new) core plugs.

It's a bit awkward to do a really good job of as the only real low point would be the water pump - and given those studs apparently like to snap, I'm not pulling that off if I don't have to.  All of the hoses come off the top of it so removing those doesn't really help much.

I get the feeling that someone may well have flushed the worst out when the core plugs were changed, given that aside from rusty coloured water for the first minute or so nothing really came out.  I was expecting to have to keep unplugging the drain tap.

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I hadn't noticed the "40" stencilled into the side of the block before.  Anyone know if that means anything?

In answer to the question of what state the bores are in, about like this.

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This camera really doesn't enjoy stuff like this.

Looks good to me, no wear lip I can feel, and you can just about still see cross hatching in the right light in person .  Nothing ringing any alarm bells for me anyway.  Not that I really expected there to be.  The engine seemed to be running okay and didn't have excessive amounts of blowby or smoke, so really wasn't looking for any issues there.

Continued as this post is now too long...
My website - aka. My *other* waste of time
Current fleet: 62 Rover 110. 73 AC Model-70. 84 Trabant 601S. 85 Sinclair C5. 88 Renault 25 Monaco. 07 Volvo V70 D5 SE.
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Zelandeth
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Re: Zel's Eclectic Fleet Blog (Volvo, Rover, Trabant, Invacar & Occasional Distractions)

#1668 Post by Zelandeth »

[] 1st October.

This lot is (finally) back together and ready to go back onto the car.

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I do now have all the consumables I need in stock so hopefully should be back together in the next few days. Based on how long everything seems to be taking me lately, that means a month or so most likely.

Definitely think dealing with the manifold to head join outside the car is the right call, getting a few of the fasteners in is awkward enough even off the car (there's very little clearance around them to get a wrench onto), would be an absolute pig of a job in situ. Whole assembly isn't unreasonably heavy anyway. I just need to make sure I have a pair of bolts on hand to drop into place once it's plonked into place as the block is at an angle and there are no dowels to hold things in position.

Not been much going on with the pinball project lately as I've mostly been fine tuning the software side of things. A couple of small finishing touches I'd been waiting for from Marco Specialities over in the US turned up this morning.

This machine has clearly only ever been set up with two coin chutes. At some point it had lost the blanking plate for the left hand slot, and a random one from another country had been wedged in place to fill the gap.

It's the red one nearest the camera below labelled "1 SPEL 25ct" so clearly not a match to our "New pence" tags.

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This has now been replaced with the proper blanking plate.

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If you had wondered what was meant to be in the big diamond shaped cutout below the coin slots you've now also had that answered - that maker's logo.

That blanking plate is designed so that it can be illuminated, though this machine has never had a lamp holder there - I will probably add that simply because it will look nicer lit up like the coin chutes next to it.

I've finally caved and ordered a proper chime unit for it. More than I ideally wanted to spend on that aspect, but given I seem to be regularly playing a few EM tables now it just needs them. Synthesised chimes/bells just sound really conspicuously naff, and it really will add to the realism.

Having little details like this ticked off is making it feel a lot more finished. Guess I really need to start getting some of the paint touched in.

-- -- --


As you may have noticed, things have been quiet. Mainly due to the arrival of this menace on the scene.

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Who now looks like this - having more than doubled in size and weight since his arrival a few weeks ago.

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Under a lot of circumstances we would probably have waited a bit longer, but Star was obviously pining after Tes, and has never not been around other dogs so was obviously struggling. All her bounce was missing. When we started looking, his litter was just about to be ready to leave mum literally the day after, it was clearly a family home rather than a puppy mill, and just ticked all the boxes. I spent a lot of time around a couple of Rotties during my childhood and early adult life and they're such lovely dogs despite their reputation. Probably the only complaint (wrong word but you get what I mean) about Tes was that while he wanted to be around you, he wasn't really interested in affection, not really surprising given the breeds involved. Rotties on the other hand are far more likely to be actively cuddly.

While he's still a young puppy so subject to temper tantrums now and then and insistent on trying to eat everything, he's doing very well and is actually very calm all things considered. Star has been getting along with him very well as we'd hoped and is back to her usual bouncy, idiotic self. Not being left together unsupervised yet obviously, but they're really wanting to properly play together.

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Not going to spam the forum with too much, but you'll see the odd photo as he grows and photos of if he does anything particularly ridiculous. Like the first time he discovered that the box I'd used to block off one area wasn't as load bearing as he'd expected.

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Shame I didn't get the camera out quicker as for several seconds all you could see was his tail sticking out the top of the box while his single brain cell was trying to process what had just happened.

It won't surprise you to hear that this has kind of put a damper on productivity (and updating here)! There have however been a few bits and pieces going on.

[] 15th October.

Second last feedback device for the pinball table landed this afternoon.

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Which are played by this trio of solenoids.

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Definitely will sound orders of magnitude better than anything synthesised. Especially as there's a proper sound box for each note involved as well.

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Goodness only knows when I'll get time to install it!

Last thing I've got planned is a pair of shell type bells for the tables which use those rather than chimes. Probably be a while before I get to those though - only a couple of tables which I play which would use them anyway.

[] 18th October.

Communism meets capitalism once again. What better car to take to Costco?

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Yes I know I also have a big Volvo estate. Don't bring logic into this. The Trabant has really become my go to daily for local work though.

It really is quite surprising how much you can fit in that boot for such a small car. I really had expected a fair bit of the shopping to end up on the back seat but it all fit in the boot.

[] 22nd October.

Turns out that our new dog has excellent taste in entertainment. I've had the TV on in the background most of the time when I've been looking after him or doing training work downstairs. Just as background noise really, both for the sake of my own sanity and because working around distractions is important. Most things have been totally ignored, but the one thing he's been pretty consistently transfixed by during down time has been Dr. Who.

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It's been forever since I've seen a lot of it so I'm using this as an excuse to go back through from the start. I can't really do anything or have anything like my usual technical videos on YouTube that I actually want to pay attention to on, as I'm keeping tabs on a small puppy piranha. So it's a good fit.

In other news another box for the pinball machine arrived this morning. Another expansion board giving me an additional sixteen outputs (and I think eight inputs).

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I knew without this I had precisely enough outputs for the chimes, but that was it. If I wanted to add anything else in the future I would be stuck. So I figured let's just future proof things. I would also have had to shuffle things a bit as the chimes require a high power output and not all channels are equal. Just sticking them on three high power channels on this board would be far simpler.

I actually had a spare hour this afternoon so got that all installed and set up.

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Wiring needs to be tidied up and integrated into the loom but I just didn't have that much time today - and I'll probably wait to do that until I've got the bells ready to go in as well.

Spot the deliberate mistake I made prepping the chime unit for installation - adding the commutation diodes to the coils.

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Yeah, I totally failed to remember that literally everything on the table has the ground side switched and the common being the positive. Derp. So yeah, those had to be de-soldered and flipped around. I realised literally the second I got the third one installed...only took five minutes to sort, but felt like a really rookie mistake.

These are actually 24V coils but we're only using 12V here. They're still plenty powerful enough even running on 12V it turns out, especially in a domestic setting where you're not trying to bash out enough volume to be heard in a noisy arcade.

As expected, it sounds *immensely* better than the synthesised chimes we had beforehand.

[] 29th October.

It might be the beginning of the end for my website. Pretty much to the day that Google introduced their AI overview nonsense my traffic dropped off a cliff. This has been even more hurt by the fact that they are now also dropping pages from the index system simply because they haven't changed recently...because you know factual information on 40 year old computers and such changes so much over time...

I honestly don't know why anyone uses it given that every time I've looked at said AI overview the information given was blatantly wrong. Not just thin on facts or slightly off the mark, just outright wrong. I didn't think the pin out for a 6502 processor was a particularly difficult thing to get right...

The simple fact of the matter is that while I enjoy writing for it on the rare occasions I get the opportunity, for the sake of one or two visitors a day that I'm now seeing it simply isn't worth the costs of the domain registration and the power usage. When it was 20-40 a day with the odd spike into triple digits it felt worthwhile, even though those are laughably small numbers in the grand scheme of things. For single digits though, there's just absolutely no point. I imagine there are a lot of content creators in the same boat so a lot of information is just going to disappear.

Bit of a shame given it's been running in some way shape or form since 2002 (or 1998 if you include the *very* first iteration - it was created as a project for a computing class). I'd been thinking about writing up the pinball project properly as well as it's been quite interesting putting that together and figuring out ways around some of the challenges on the way. However what's the point of spending probably several tens of hours writing a page up, putting all the necessary references together etc, if nobody will ever see it?

[] 7th November.

Was having a random thought after a post on another forum this afternoon regarding the concept of a "it really DOES do everything" car and if I could pick one.

After a surprisingly large amount of thought I came to the conclusion that I had driven what for me would be the best candidate I can think of - and indeed even tried to import it at the time. It was this beastie I did a bunch of miles both behind the wheel of and as a passenger back in 2014 when we were visiting family in Michigan.

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A 1998 Chevrolet Astro.

The equivalent over here would be a Transit Torneo. They're both van shaped...that's about where the similarities end to be honest though. Which becomes very apparent as soon as you open the door.

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No park bench seats here, there's more padding on there than your average sofa. Only car I can think of which presents the same level of seat squidge would be my Renault 25.

First row of seats in the back are similarly well trimmed.

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Rearmost seats are still more comfortable than most front seats made in the last 20 years.

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With both rows of seats in place - unlike most 7 seaters - you still have a decent amount of cargo space. Plenty for everyday use or a couple of dogs to travel in.

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Either or both of those rear seats rows can be removed in a couple of minutes.

Obviously it's extremely versatile. However it achieves that without the need to feel in the slightest utilitarian. On the contrary, while there's none of the hallmark items like the lashings of false wood or carbon fibre which seem to be needed for perceived luxury, it is honestly such a comfortable thing to travel in. Huge squishy armchairs, soft long travel suspension, 70 profile tyres, finger light controls, I'll take that over anything coming out of Germany today thanks. The longest run I probably did was five hours or so, including dealing with rush hour Detroit traffic and concrete slab construction roads as are the norm in that area. It felt like I'd been on the go for about half an hour.

Performance is another area where there's a bit of a void between this and anything made this side of the Atlantic. Over here that would probably have a diesel engine of somewhere around 2 litres, maaaaybe 2.3 at a stretch. This instead makes do with a 4.6 litre petrol V6. I don't think the actual headline power figure is all that spectacular, but it's got torque for days. It barely needs to come off idle in normal driving, but if you do put your foot down it will stand on its back end and take off down the road unfeasibly rapidly. In the case of this one which I'm pretty sure had shed some of the baffles from the exhaust, making an absurd angry V6 howl. The fact that it's such a torque monster meant that it wasn't actually horrifically bad on fuel either as the engine barely had to come off idle until you're on the motorway.

This was one which I really was sad to hand the keys back for. To the extent that I did actually look into the possibility of getting it imported at the time but I just couldn't find a way to do it in a way that I could afford (we had just bought a house!).

While it doesn't look as swanky as the Volvo, it does absolutely everything it does, as well and in even greater comfort and with even more space to play with.

I have had a look at these a few times since, but all of the ones I've found in the UK are either day vans which don't have any of the versatility that really makes this shine or panel vans. Nobody really bothered to import these "standard" ones in any numbers. I did find ONE a few years back - though it had been partly dismantled for a camper conversion which stopped once they found a bunch of rust, and then half the bits that had been removed were lost, suffice to say I walked away from that.

It's entirely a thought exercise, but if I did find one of these in as good shape as that one was I'd definitely be seeing if I could get hold of it. That condition is a challenge in itself as well given these are vehicles which tended to live hard lives.

So ends a random thought experiment that started earlier this evening.

[] 13th November.

Over the last week the Trabant has been at the back of the stack on the driveway, and as I've been generally short on time I've not had the opportunity to shuffle cars to get it out. Plus I don't tend to drive it so much in the rain as I've still to sort the leak from the windscreen that completely unavoidably drips on my right knee. That understandably gets old in a hurry!

Despite that one day Chris was working in the office because it's so small I was able to sneak it out through the gap - after driving the Volvo for a week it felt incredibly light and nimble.

Also noticed the other day that when I adjusted the throttle cable I must not have had it fully seated at one end so there was a bunch of slack in it. Given the pretty small amount of travel a couple of millimetres equates to a fair difference at the carburettor slide. Having tweaked that has definitely made it feel more peppy - and around town in particular it wasn't feeling at all lacking in pep beforehand.

I think I have tracked down the source of one annoying clunk from the back of the car - which I've had three theories already that I was pretty certain were responsible for right up to the point I fix them! Well there are actually a couple which present themselves on really harsh bumps (the New Bradwell Asda carpark speed bumps are usually responsible as they are exceptionally aggressive - the Volvo drags all four mudflaps over them they're so tall). There should be some rubber feet under the rear seat frame. With them missing it's able to float a little and will crash to the floor in situations like that. The bootlid also flaps around a bit because the seal is knackered. Those are both easily identifiable noises though, rather than the "sounds like something rolling around in the boot" sort of noise from the offside rear corner which would sometimes happen at other times. Reckon I've got it!

The sealant between the rear quarter body panel and the rear panel has failed. It's still screwed to the frame at the top and bottom, but the middle is able to flex a fair bit along the join highlighted below.

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I suspect when you apply forces in just the right way things are able to open and close that gap a bit - resulting in the sort of hollow knocking I'm hearing.

Easy enough to sort with a bit of Sikaflex (basically the modern version of what was originally used) squeezed into the join - can do it from inside to minimise mess. I'm not getting into removing the seven hundred screws - most of which probably need drilling out - from the top to fully remove the panel at this stage. That no doubt will unveil a veritable cornucopia of repairs needed to the wheel tub and probably the bottom of the B pillar given the age of the car and other owner's experiences. A body shop will be getting involved to sort the rear screen surround at some point. That will require removal of this panel - any horrors within can be dealt with then. I'm not actively going looking for trouble, especially when knowing "yes I'll need to sort that" really doesn't gain me anything as I'm budgeting for it anyway. If everything is surprisingly clean in there when the panel comes off that's just a bonus.

[] 17th November.

Despite the puppy shaped time sink, I finally had a little bit of spare time yesterday afternoon when I both had a bit of energy and it wasn't chucking it down with rain so got stuck back into the Rover at long last.

Before:

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After:

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I only had half an hour so still a bunch to do, but the head is on and properly torqued down. At least it's not open to the elements now (rocker cover was sat in place before I tidied up). Hopefully one more session I'll have the engine running again with a bit of luck.

Of course I remembered to change the O ring which is sandwiched between the water pump casting and the bottom surface of the head. Which is often the reason the heads need to come off on these cars.

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Hard to tell in the photo but the old one is crushed to about half the height of the new one.

Just glad I've actually done *something* with it for a change.

-- -- --

24th November.

Bit more progress has been made during the snippets of time I've had in the last couple of afternoons.

This is where we left off on Saturday.

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Almost looking like an engine again.

[] Head bolt torque values re checked. As expected things had settled a bit and there was a bit more travel available especially towards the centre.

[] Rocket shaft retainers properly tightened down (they don't need to be very tight - manual only calls for 12 lb/ft).

[] Distributor put back in place. Thankfully my timing quandary didn't come to anything as the shaft is keyed such that it can only go in two positions and I had a photo during strip down which let me see roughly where the rotor was pointing.

Before I put it back in place I spent a bit of time getting the vacuum advance unit moving again. Thankfully the diaphragm is fine and with a little penetrating oil and care I was able to get it moving again. I may need to replace it long term but we'll see.

[] Cylinder head oil feed line reconnected. The feed to the top end on this engine is external and connects to the head via a banjo bolt on the back of the head. I only dropped one of the copper washers down the back of the engine twice. Not difficult this one, just fiddly.

[] Coolant lines hooked back up. This is somewhere I've learned some things it seems to make my life a bit easier. The line which runs from the underside of the inlet manifold to the heater core is a royal faff to fit.

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The reason is that this is actually two hoses - joined in the middle by a little metal stub bolted to the back of the manifold. Trying to get the hose clips fastened with it in situ is a massive pain as there's something in the way no matter which way you attack it. Top one is merely frustrating, but the bottom one is absolutely maddening.

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Solution? Attach the two pipes to that awkward stub beforehand and then just put the one screw that holds the bracket in place.

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I really wish I'd twigged that I could do that both of the last times I had this off - I must have spent the best part of an hour swearing at it when I put the new lines on here. This way took about five minutes.

[] Oil drained and changed. This took an age as it's cold, there's nearly 10 litres in there, and 20W50 doesn't exactly like to flow when it's cold. What came out wasn't horrible, but there definitely was some water contamination. It also smelled quite fuelly, though given the idle was absolutely stinking rich when the car arrived that doesn't particularly surprise me.

In terms of adding new oil I ran out of patience after a couple of minutes and just abandoned the can here while working on other things.

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That whole can juuuuuuust about gets it onto the dipstick. That's quite painful given this will be getting changed again after an hour or two of running given the cost of oil these days.

[] In a similar subject of ludicrous fluid capacities, the cooling system was filled up - that takes 14 litres! Ten just about covers the fins in the radiator, but I've not started bleeding anything yet and the heater core is the highest point in the system so it will drop a bunch once the engine starts I expect. I have done the best I can to flush the system and radiator out but we'll just have to see how clean the new coolant stays for how long.

[] Valve clearances roughly set - the inlet side needs to be done with the engine hot so I've just made sure we *have* some clearance on all six rather than being massively too tight. Haven't touched the exhaust side yet (which of course haven't been messed with) but I'll do the lot properly once the engine has run.

Sunday evening I managed to get a bit more done as the last dregs of daylight faded and the rain arrived. Working in the rain by torch light is so much fun.

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[] Carb refitted. After I un-mutilated the throttle return spring bracket (guessing it got pranged when the brake servo was being replaced). I don't actually have the correct return spring on hand but I'm sure I can find something that will work better than the current one which is vastly too long. The front nut is precisely as annoying as I remember - I really need to get a properly skinny 1/2" ring spanner for this as it would reduce the profanity level considerably.

[] Throttle linkage reattached. With a little bit of free play in - there was none before and this both made the throttle tend to hang just off idle, and made it waaay too sensitive at the low end making it near impossible to pull away smoothly.

[] Vacuum lines hooked back up, all two of them. Hugely complicated job that. There is one more that needs to be blocked off before the engine will run - that big one you can see at the top of the carb float chamber. That's normally fed from an orifice in the air cleaner ducting - so if that's not fitted you need to block that off or it will behave like a giant vacuum leak.

[] Wiring to temperature gauge sender and choke warning light thermoswitchs reconnected.

[] New rocker cover gasket and rubber seals on the retaining nuts replaced.

Between us and a test run I think there's just me sorting out the slightly mangled ignition coil bracket, installing that, connecting the distributor and hooking up the HT leads. Then *hopefully* we can go for a test run. The fan belt could do with adjusting as well. Which I kind of wish I'd realised before I put the head back on as the adjuster would be far easier to get at without all that being in the way.

The engine has rotated though (and spun over long enough to get oil pressure) and there weren't any untoward noises at least and we appear to have compression, so that seems a decent starting point. Plus since yesterday evening the coolant and oil have so far remained properly separated. Fingers crossed we'll have a running engine again soon.

You are now up to date.
My website - aka. My *other* waste of time
Current fleet: 62 Rover 110. 73 AC Model-70. 84 Trabant 601S. 85 Sinclair C5. 88 Renault 25 Monaco. 07 Volvo V70 D5 SE.
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Zelandeth
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Re: Zel's Eclectic Fleet Blog (Volvo, Rover, Trabant, Invacar & Occasional Distractions)

#1669 Post by Zelandeth »

I threw the ignition system back together this afternoon (with a shim in the ignition coil bracket... I'll fix it properly another day when I'm not so pushed for time). Sure enough after a little fiddling around with the choke as the cable isn't hooked up yet, had the engine running pretty quickly.

Running on about four cylinders. With visible bubbling along the edges of the head to block join.

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Well that's sub optimal.

I will triple check my work tomorrow, but I suspect I may have an answer in front of me to the question of whether the head needed some machine work. One suggestion that's also been made is that I should have annealed the gasket before installing it...if indeed that is required that would indeed explain how it's so much worse now than where we started out.

That step isn't mentioned in either of the manuals I've got though nor on the suppliers listing. I know I've done this when reusing metal gaskets on some small engines or the flat copper ones on an old flathead Ford V8...but it's definitely not something I've ever had to do to a new out the box gasket. They've always been ready to go. So I don't feel entirely stupid for not having twigged that was something I might need to do. If that's the case though fair enough. Lesson learned. I fully expect there to be some learning experiences working on a car with it's design roots back in the 40s and this may be today's one. Not the end of the world so long as the head hasn't been damaged - gasket is only £15 and it's probably an hour and a half of work to pull and reinstall it again.

Probably the most painful part is going to be having to change the oil and most of the coolant again! I'm glad I only put enough oil in to get a safe reading on the dipstick now so that won't kick me in the wallet quite so badly.

I need to do some digging to confirm whether I DO need to treat the gasket in any way though. Only comments either of the manuals I have make is that I absolutely must not use any jointing or sealant compounds on it. If it is indeed supposed to be good to go there's obviously something else in play.

So not a particularly cheerful update, but I'm not too bothered. Every day's a school day after all.
My website - aka. My *other* waste of time
Current fleet: 62 Rover 110. 73 AC Model-70. 84 Trabant 601S. 85 Sinclair C5. 88 Renault 25 Monaco. 07 Volvo V70 D5 SE.
rich.
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Re: Zel's Eclectic Fleet Blog (Volvo, Rover, Trabant, Invacar & Occasional Distractions)

#1670 Post by rich. »

Good to see progress on rover.. the pinball machine looks fantastic, have you thought about making and selling them as an extra source of funds for the fleet.. :thumbs:
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