Chassis

Varex exhaust build part 4

As I was busy Richard sorted the wiring out for the control box:

Wiring, inside the tub running along the tank with the rest of the rear loom

Wiring running along transmission tunnel, protected by a piece of fuel tubing to stop stray debris from damaging it.

Behind the fuse box, hooked in via 7.5amp fuse to an ignition feed

Located the control box in the same area just off the centre console.

Everything back in place under the dash

Just needs the rear putting back together again.

Engine Work

MTX-L Calibration

Calibrated the sensor today on the bench.

Important note – the big plastic plug that you connect to the sensor has a little plastic tab which stops the plug coming undone without pulling it. If you connect the plugs without lifting it then it can very easily go the wrong side of the plug (inside) and stop it connecting up properly. You’ll know it’s right when you hear a click as it slides into place – as below:

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First step is to hook ground and power up to the gauge with the lambda sensor disconnected. It will display E2 on the screen, wait 30 seconds and take the power off.

Plug in the O2/wide band lambda sensor and reapply power.

The sensor will get hot:

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HTR will be show on the display for a period of time while the heat builds up. My bench power supply showed between 1.4 and 1.7 amps being pulled while it was doing this.

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It briefly shows CAL is the display while calibrating the switches to 22.4 as it is in free air:

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That’s it ready to go in the car – don’t power it up without the lambda sensor attached or it will reset the calibration.

Chassis

Vents and washer bottle

Demister vent tubing made out of some drain pipe<br />

Demister vent tubing made out of some drain pipe

Scuttle vents, these are from a mini with some stainless mesh added.<br />

Scuttle vents, these are from a mini with some stainless mesh added.

Plastic tubed sprayed black and glued to scuttle. Some black rubber acts as a connector to the pipe that came with the heater<br />

Plastic tubed sprayed black and glued to scuttle. Some black rubber acts as a connector to the pipe that came with the heater

a view of the rubber connection on the heater vents<br />

a view of the rubber connection on the heater vents

Centre console covered with heater vent built in to direct the warm air at your feet.<br />

Centre console covered with heater vent built in to direct the warm air at your feet.

Scuttle on with heater pipes attached<br />

Scuttle on with heater pipes attached

Vent pipes attached to scuttle<br />

Vent pipes attached to scuttle

Bracket to attach screen wash bottle<br />

Bracket to attach screen wash bottle

Screenwash bottle holder<br />

Screenwash bottle holder

Screen wash tube going through the firewall<br />

Screen wash tube going through the firewall

Screen wash bottle and motor installed.<br />

Screen wash bottle and motor installed.

12V accessory socket for the GPS<br />

12V accessory socket for the GPS

Bodywork coming together<br />

Bodywork coming together

Sorting out the wiring under the scuttle<br />

Sorting out the wiring under the scuttle

Sorting out the wiring under the scuttle<br />

Sorting out the wiring under the scuttle

Wiper motor and connections.<br />

Wiper motor and connections.

Bodywork

Getting there

I was hoping that the car would get finished today, but as always there were more and more little things to do!

The centre console now has bracketing to hold it securely in place, the tub is secured and positioned right for the doors. The doors with re-enforcement brackets are on but not adjusted yet. The demister vent connections are nearly done. I tried setting up the amp with the scope but either them is chucking out some funny signals or the scope is on the blink. Headunit has clean output to setting 60 of 62. Higher than 60 and you get a tiny bit of distortion creep in.

Once the demister vents are sort the scuttle can go on and the doors adjusted. After that it’s just bonnet side panels and head lights.

Interior

Fuse box & speakers

Mk 2 fuse holder bracket<br />

Mk 2 fuse holder bracket

This bracket also holds the wiper motor. The clamp has been moved up a bit to reduce flexing.<br />

This bracket also holds the wiper motor. The clamp has been moved up a bit to reduce flexing.

The centre console is taking shape with a small recess to keep your glasses.<br />

The centre console is taking shape with a small recess to keep your glasses.

Managed to find some room to fit a speaker above the steering column.<br />

Managed to find some room to fit a speaker above the steering column.

There's some sides and top to try and keep the front and back separated as much as possible.<br />

There’s some sides and top to try and keep the front and back separated as much as possible.

Once the dash is in you can't see it any more.<br />

Once the dash is in you can’t see it any more.

Interior

Speakers, hazards and other stuff

Nose cone and centre console

Nose cone fitted.

hmm pretty colours

Starting to piece together the centre console

Two supports cut and shaped to get the angle of the radio correct with enoughclearance for the rear of the radio.

Radio supports glued.

Just need to make up some sides to hold the midbass speakers under the dash.

Bodywork

Interior and rear lights

Dash board re-trim without glove box (wiper motor in the way)<br />

Dash board re-trim without glove box (wiper motor in the way)

Rear of re-trimmed  dash showing pod for speaker<br />

Rear of re-trimmed  dash showing pod for speaker

Divers side behind the dash<br />

Divers side behind the dash

Test fit on car, the mount holes needed drilling out as the paint had filled them a bit.<br />

Test fit on car, the mount holes needed drilling out as the paint had filled them a bit.

The speakers could do with a grille mesh to finish them off but other than that it is coming together.<br />

The speakers could do with a grille mesh to finish them off but other than that it is coming together.

Rear lights installed with new waterproof plugs - a bigger job than you might expect!<br />

Rear lights installed with new waterproof plugs – a bigger job than you might expect!

Interior

Interior

DVLA Inspection took place today so with any luck we’ll have a tax disk and reg number in a about a week!

Some final touches to the interior, thanks to Bilal at Strom Motorwerks for the custom engraving