How much torque can you put through the key on the front pulley? 12kW has got to be close-ish to the sum of all accessories (alternator, air-conditioning, water pump). 12kW is like 3 air conditioners.

If you drive the generator from a belt off the flywheel side you can choose to drive it any direction you want just by orientating the generator relative to the motor. Easy.

If the 120Y master cylinder is the same as the 1200 there's a purge nipple on the master cylinder you have to do first. Different to every other car I've worked on. That may have been the issue. One of my least favourite jobs.

My car projects are on hiatus with a new old house and a new baby so there's not much for me to post about not that I've ever been a big poster. It does seem like Facebook gets a lot more traffic. I guess many people are on it anyway. I do wish there were a few more projects to read about while I can't get to mine.

Going too big can give you trouble at idle. It gets to the point where you can't get a short enough squirt for idle fuel mix. How big is too big, I don't know. Depends on many things. Someone else may have experience with a set up like yours.

It might be slightly more fun than the Mondeo wagon I drive! The baby capsule fits better in the Mondeo though, I don't reckon the 1200 coupe has the mounting points or curtain air bags. From what I can see with my colleagues I should be thankful I've still got a toy car after starting a family.

That does look good. You'll need a little mirror to show everyone how beautiful your gearbox mount is

The old systems can be retrofitted with different throttling valves for the R134a assuming it's not a capillary tube system. I had this done on an old car (91). Worked fine.

Work insecurity sucks! I hope things pick up for you.

Galling is a type of wear where metal cold welds between the rubbing surfaces. It then either keeps them welded together or tears off one of the surfaces. It won't happen if there's an oil film in between, galling requires similar or the same material and enough contact pressure to push contaminants out the way and get virgin materials in molecular contact.

316 stainless galls quite easily when self mated. Sorry if it's a bit hard to understand.

This is what I was thinking of http://mitsubishilinks.com/fsm/acl_pistonproducts_pp99.pdf, they have piston specs for many models in there. Sorry if I'm a bit too slow. I'll enjoy watching the build!