These pages show the build from the start 20 entries at a time!
11/12/2005
Exhaust Test Fit
Stock exhaust system test fit. The stock exhaust is a two part system. Today we test fitted the manifold and first part to see if the steering column clears it. It does which is good! Seems the issue with the steering column is that the hole in the bulk head is in the wrong place. If its moved over then the steering column will bolt on to the mount without an adapter plate.
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In a strange twist the postman showed up today, Sunday! The replacement clock from Marlin arrived, this one now matches the rest. They look really good all lined up together.
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In a strange twist the postman showed up today, Sunday! The replacement clock from Marlin arrived, this one now matches the rest. They look really good all lined up together.
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12/12/2005
We're back!
Seems the site has been a bit of a drain on the server it was located
on, so now its been moved to a shiner happier place with more
available resources! Sorry for the down time.
28/12/2005
Time to think
The holiday season has given us time to sit next to the car and think about
how and where to run things. The intake is going to be a rather
interesting one. I'll let the pictures do the talking once all the bits
turn up from Rally Design.
On order are silicon hoses, ducts, oil cooler and pipes. After further consideration we're moving the rad further forward, placing the oil cooler in front and getting a "sucker" fan instead. The current position places the rad too close to the engine for me to be comfortable with. We're going to follow Robin's layout for this one, along with his solution for the oil cooler. Thank you for all your help on that one!
Also up for work is the steering column. After enlarging the hole on the bulk head we were able to mount it using the bracket already in the car. However after spending some time sitting in the driver seat we both agreed we didn't like the alignment and have decided to customise it. Using the brake we already made and the now enlarged hole I think we have a steering position that suits our personal taste.
The brake pedal - after several hours of going nowhere trying to bend it, it's time to call in a professional. This stuff is too thick for our weedy gas burner and vice to bend.
Pictures to follow at some point this week.
On order are silicon hoses, ducts, oil cooler and pipes. After further consideration we're moving the rad further forward, placing the oil cooler in front and getting a "sucker" fan instead. The current position places the rad too close to the engine for me to be comfortable with. We're going to follow Robin's layout for this one, along with his solution for the oil cooler. Thank you for all your help on that one!
Also up for work is the steering column. After enlarging the hole on the bulk head we were able to mount it using the bracket already in the car. However after spending some time sitting in the driver seat we both agreed we didn't like the alignment and have decided to customise it. Using the brake we already made and the now enlarged hole I think we have a steering position that suits our personal taste.
The brake pedal - after several hours of going nowhere trying to bend it, it's time to call in a professional. This stuff is too thick for our weedy gas burner and vice to bend.
Pictures to follow at some point this week.
29/12/2005
BSP / UNF / NTP errr
After some research and head scratching (whats an inch?) we've been able to determine that the thread sizes on the Marlin supplied oil pressure and temp sensors are 1/8"x27 NPT. The thread size on the engine for the temp sensor is 14mm x 1.5 and for the oil its 12mm x 1.5.
30/12/2005
Pictures!
02/01/2006
Intake System Version 2
05/01/2006
Sensors
08/01/2006
Brakes!
We got the brake pedal back from a friend who was able to bend it for us. Now the positioning is much better giving more room between the accelerator and brakes (we've got big feet!):
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09/01/2006
Hi Res!
New hires gallery, a few shots from the garage to start with, next time the cars outside this section will grow.
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23/01/2006
Order and tank
Order from Car Builder Solutions turned up today, placed on Friday afternoon! One heater and plume, a rivnut gun, universal band and a set of dash warning lights (I really didn't like the ones that came with the kit so I order these instead)
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Seeing as I have a few days off, I've taken the tank to a metal workshop in Chandlers Ford to add a mini surge tank to the bottom. The tank is not baffled and it £250 to buy the surge tank and twin pump set-up from Marlin. I've decided to modify the main tank and see how it goes first. If I get problems I can always add a surge tank in the front and a second pump at a later date.
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Seeing as I have a few days off, I've taken the tank to a metal workshop in Chandlers Ford to add a mini surge tank to the bottom. The tank is not baffled and it £250 to buy the surge tank and twin pump set-up from Marlin. I've decided to modify the main tank and see how it goes first. If I get problems I can always add a surge tank in the front and a second pump at a later date.
12/02/2006
Tank, oil, water pipes
19/02/2006
Water pipes, radiator brackets v3 and oil pipes
Time for another version of the radiator bracket! Its now bolted along the sides with two strips of metal either side of the rad. Bolts need shortening to and a lick of paint to clean it up.
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All the water pipes for the front of then engine are now cut to size and routed. Currently the bottom pipe is zip tied to the bottom of the radiator - I'd like to find a more elegant solution for this but it will do for the moment.
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Oil pipe test fit, not sure yet how we're going to run these so these are just where they will fit at the moment. The oil cooler connectors we have are the straight type so are most suitable for running the pipes this way. 180 degree connector would work for going under and along. More research needed on this one!
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All the water pipes for the front of then engine are now cut to size and routed. Currently the bottom pipe is zip tied to the bottom of the radiator - I'd like to find a more elegant solution for this but it will do for the moment.
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Oil pipe test fit, not sure yet how we're going to run these so these are just where they will fit at the moment. The oil cooler connectors we have are the straight type so are most suitable for running the pipes this way. 180 degree connector would work for going under and along. More research needed on this one!
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26/02/2006
Fuel Tank
Today we installed the fuel level sender in the fuel tank - sounds easy but it took most of the day! Stage 1 was to figure out the numbering system as the chart that came with the sender only when down to 180mm deep tanks. The Marlin tank is 160mm. Luckily it was quite an easy one to figure out - 160mm depth, 67mm pivot, 63mm radius.
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Next on the list was to make the hole that the send goes in. It was all going well until the dremel (110v 20 odd year old model) finally giving in and died leave the rest of the cut out and clean up to me done by hand. Still turned out quite nicely:
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There was a lot of mess in the tank, but luckily one of the vacuum cleaner attachments fits in the hole!
This only leaves figuring out how to attach the fuel hose to the tank and mounting the filter/pump!
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Next on the list was to make the hole that the send goes in. It was all going well until the dremel (110v 20 odd year old model) finally giving in and died leave the rest of the cut out and clean up to me done by hand. Still turned out quite nicely:
Click me
There was a lot of mess in the tank, but luckily one of the vacuum cleaner attachments fits in the hole!
This only leaves figuring out how to attach the fuel hose to the tank and mounting the filter/pump!
05/03/2006
Busy Weekend
12/03/2006
Power!
A quick trip to B&Q and one hardcore MAPP blow torch later the two oil pipes are bent out of the way of the steering column with ease!
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CBS Throttle cable through the bulk head. The thread on this had to be chopped back so the pedal could move all the way up. We've bolted on throttle cable at the other end - the cable is current 5m long which is a bit much! The throttle is still a bit stiff with the long cable - We're hoping that it will loose a bit once its shortend.
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Parts from the donor heater system - The two pipes use opposite connector types therefore when connected we can use this as an inline electric controlled valve to regulate the amount of hot water that flows through the system from a control on the dash - much nicer than a manual valve hidden under the dash!
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CBS Throttle cable through the bulk head. The thread on this had to be chopped back so the pedal could move all the way up. We've bolted on throttle cable at the other end - the cable is current 5m long which is a bit much! The throttle is still a bit stiff with the long cable - We're hoping that it will loose a bit once its shortend.
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Parts from the donor heater system - The two pipes use opposite connector types therefore when connected we can use this as an inline electric controlled valve to regulate the amount of hot water that flows through the system from a control on the dash - much nicer than a manual valve hidden under the dash!
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19/03/2006
Heater and fuel
Heater pipes added - CBS sent the wrong size pipes - too small, managed to get them on anyway but they kink on the bends so will have to replace them. Probably with two 90 degree silicon hoses.
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Fuel pipe straps - Doh! hmm should really have though of this before making a big hole in the tank - never mind just moved the straps over.
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Fuel pump, filter and connection in place:
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Fuel pipe straps - Doh! hmm should really have though of this before making a big hole in the tank - never mind just moved the straps over.
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Fuel pump, filter and connection in place:
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22/03/2006
Pump Issues
Doh! We've been advised that the Facet pump is not up to the job in a fuel injection system. So we ordered a Sytec PF603 from www.raceparts-direct.com instad with is spec'd for the job.
If we add a swirl pot at a later date we could still use the Facel for the low pressure pump!
This weekend brings the rather interesting task of measuring all the pipes on the engine to order up hose clips!
If we add a swirl pot at a later date we could still use the Facel for the low pressure pump!
This weekend brings the rather interesting task of measuring all the pipes on the engine to order up hose clips!
26/03/2006
Spaghetti Junction
Wire, wires everywhere! We've started on the loom this weekend while waiting for the fuel pump! There's only a few bits on
construction work left, the main one being the brackets for holding the AFM,
air filter and header tank. There's a few minor bit hose left and lots of hose clips!
On to the pictures, some working in progress on the wiring loom:
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On to the pictures, some working in progress on the wiring loom:
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02/04/2006
More brackets
Decided to use the BMW header tank using Robin's car as a model!
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AFM bracket part 1 - this fixing is not yet strong enough - the metal flexs too much to hold it safely. We'll need to add a more solid metal bracket up from the bottom. Other end of the bracket - holds the carbon air box and the bottom of the header tank. The carbon airbox can be moved further forward by shortening the blue silicon hose making more room at the back for an intake pipe.
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This bracket used to hold the diagnostic port in addition to the two sensor plugs - there's not much room here any more so were going to move the diagnostic connector else where. The bracket has been cut and attached at a different angle to normal.
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AFM bracket part 1 - this fixing is not yet strong enough - the metal flexs too much to hold it safely. We'll need to add a more solid metal bracket up from the bottom. Other end of the bracket - holds the carbon air box and the bottom of the header tank. The carbon airbox can be moved further forward by shortening the blue silicon hose making more room at the back for an intake pipe.
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This bracket used to hold the diagnostic port in addition to the two sensor plugs - there's not much room here any more so were going to move the diagnostic connector else where. The bracket has been cut and attached at a different angle to normal.
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