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Alternators ground through their mounting. It is worth checking that there is no paint or corrosion on the mounting points both the bracket to the alternator and bracket to engine block. If the car starts then the engine return to the battery is good or the starter would not get enough current. If the rectifier in the alternator has a diode gone it can put out a lot of noise. The thick cable takes the charging current to the battery. The thin cable normally goes to the ignition light on the dash board. The fact that the engine revs to 2K before the alternator kicks in shows a problem as the alternator should start charging below 600RPM engine speed. This could be down to the alternator having the wrong bulb in the dash or a wiring error or internal problems in the alternator.

The vast majority on modern 4 and 6 cylinder engines use wasted spark and use the same plugs in all positions. The makers just expect owners to replace the plugs more often. The platinum plugs ford fitted originally are not cheep but will last a long time.

Hood repairs are doable. Easy depends on appearance after the repair. I have glued and sewn a patch on the inside, from the outside the repair can be seen but it keeps the rain out. From the inside it is obvious.

Thread on fordownersclub. It appears Henry installs the two types of plugs when the engines are supplied new, it's something to do with the wasted spark ignition, and there is a correct position for each type, being: Timing belt end P1 / PG1 / P1 / PG1 Special thanks go to Jonathon Kay for his BM and link to www.fordownersclub.com

There is a problem of dates here as the Exmo kit was produced in 96 to 97. If you built in 86 it was probably a triumph based kit.

The plug has the same fitting and will fire the near enough the same. It is one heat range hotter so at full power it might have problems but at low to medium power it could be used to see if this is the problem. APR6FS is the recommended plug for 2l Pinto engines.

Yes I assumed that there would be a suppressed version. APR6FS could be used to prove that this is the problem.

You could try APR7FS.

what spark plugs are you using? ones with a resistor have R as part of there part number. For instance on my pinto engine I use NGK APR6FS which has a R as part of the code. The resistor acts to reduce interference. I understand that the AccuSpark leads are resistive. resistive.

Is the new cam an upgraded cam? Most non standard cams require timing to be set, often with vernier pullies or offset keys.

Are all cylinders the same? Just thinking back 40 years pintos were notorious for trashing cams due to bad lubrication. Ford changed the cam spray bar to fix. So cam cover off and examine the cam, whilst you are at it check valve gaps.

I am Warrington so not that local.

Forecast is not good. If I come might be in the Saab.

I think that you left the same time as I did. Traveling north west was obviously better than nearly west ( with a detour south), I am glad that I chose the cat and fiddle.

Interesting read. Hears to some enjoyable driving.

Out of curiosity I was there for sunny Saturday but did not stay to Sunday. Was the weather rain as predicted Sunday? I got home just in time to garage the car before the heavens opened. Had a good time with driving over the Cat & Fiddle in the morning through heavy mist but clear on the way back.

Drilling stainless Rule 1 do not let the stainless get hot as it goes very hard. Center punch to locate the hole. Cobalt drill bit at low speed with some pressure and low speed. https://www.screwfix.com/search?search=cobalt+drill+bits+for+metal Be careful of the swarf as it is normally very sharp. As for sewing the sewing needs to be waterproof sealed for most materials. There are tapes for this that go on the inside.

Have you tried woolies? https://www.woolies-trim.co.uk/

I regret to say that I wont make this but hope to see folks at Newark.

I had a couple of old style minis with A series engines that did not have a separate expansion tank. There was a level indicator in the radiator giving the level to fill to when cold. Never had a problem of overheating. The top tank was the expansion tank. I run my car a similar way and since I sorted out the fan have only had an overheating problem when the fuse blew. I had put in a fuse that only just allowed the fan to work next size up sorted.

2B is larger than a Caterham so I doubt that it will fit.

What ignition system have you got?

Richy has a good point. I would add an old trick checking for spark breakdown is to close up the gap in the spark plugs to about half which reduces to voltage but limits power at the highest end. Obviously a tempory diagnostic mod.

could it be misfiring? When under load the spark voltage goes up which can lead to breakdown in the coil or leads instead of at the end of the spark plug. You could try changing the coil pack.

Early sierra to about mid 85 had horn push in center of steering wheel.