Wiper Installation

After spending a lot of time eyeing up the location for the wipers I came to the conclusion that 90 degrees would work best for us. After looking inside the gearbox I found that we have a 110 degree drive gear (which matches the sweep measurement I took a while ago). So I ordered a 90 degree drive gear.

Wiper wheel boxes installed. I had to thin down the fibreglass on one of them as it was too thick to mount the wheel box.

The boxes are fairly in-line.

Motor mounted on a metal plate. I plan to move the hoop for the motor a little hight so the motor is held a little better. Its seem to hold fine as it is however I would feel better with it moved.

Tubes cut to length and flared, good that we had all of the tools from installing the brake pipes as they came in perfectly for this job.

All the parts ready for install. We bought some chrome tops for the wheel boxes as Marlin supplied rubber ones. I am using the rubber ones for fitting to avoid damaging the the chrome ones.

Wipers installed, still need to cut the arms to the correct length.

Tubes Installed.


Wipers in motion.

Washer jets installed.


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Louvre Project

The ITB projects a bit quiet right now as we’re trying to get the car ready for paint. Part of the this is a set of louvres.

I’ve probably spent 16+ hours on the lathe with these, the curves were right headache!

Test results so far are OK, but not perfect. The thing I’m have the biggest problem with is getting a nice start and finish. I think I’m going to have to make up a wooden die I can use to hammer a nice finish to the start and ends.

They are for this machine:

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ITB’s continue

A bit more progress today in preparation so the manifold can be completed. I couldn’t quite run the pipes at the same angle as the holes in the head due to using the stock manifold. I’ve opted for a shallower angle that will result in a relatively smooth transition between the pipes, manifold and head. I could always completely custom make a manifold at some point in the future.

The other big step was to get the throttle bodies properly spaced. I cut 10 spacers on the lathe exactly 11mm wide. There still a lot to including the minor issue of welding the pipes on – not sure how this will work but I suspect it will involve doing a lot of grinding to clean it up!

<p>Ali tubes cut</p>

Ali tubes cut

<p>Quick test fit</p>

Quick test fit

<p>"just" needs to be welded!</p>

"just" needs to be welded!

<p>And from the other side (yeah the throttles are the wrong way round ;o) )</p>

And from the other side (yeah the throttles are the wrong way round ;o) )

<p>Spacers cut on the lathe to space each throttle 11mm wider than they are on the GSXR</p>

Spacers cut on the lathe to space each throttle 11mm wider than they are on the GSXR

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ITB Idle Control

I’ve been research idle control on these. The GSXR has a manual fast idle lever on the bar. Some people have experimented with a stepper motor to control this, but I think I’ll probably employ the solution that BMW themselves use on the M3’s – a common vac pipe connecting all 6 cylinders and a standard ICV bolted up to it. I can use the second set of injector holes that are directly on the throttle body.

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ITB’s continue

Two sets of ITB’s give you 4 bolts to screw them together – not long enough for 6 throttles. The solution is to chop the thread off two of them and the head off the other two. Then the 4 bits are welded together to create one long bolt.

After welding the join is ground down to make it round and smooth.

Which means with temporary spacers its all one piece now

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ITB Project

Another project dreamed up during a cold, wet winter not driving:

Two sets of these GSXR 600 K3 throttle bodies:

GSXR 600 K3 Throttle Body

An spare M20B25 intake manifold

A number of hours with  a hack saw, angle grinder and piller drill on the lathe with a milling bit later:

And you get a nice manifold ready for some ali tubes to be welded on:

The manifold will slot right on being the mounting face of a stock intake as can be seen below:

The nice thing is that the provision for the oil return is already integrated to there’s not need to come up with a solution for that:

The stock fuel injection locations will be used, those on the GSXR will be plugged.

The GSXR individual throttles need spacing further out than that standard so some modification will be required to make this work. The K3’s have a second set of throttle butterflys controlled by the ECU, these will need removing and the extra holes plugging. The end piece as a TPS integrated. The diameter of the GSXR bodies is 38mm at the engine side, they are tapered and open up a bit more to the intake side. Based on recommendation be other ITB users on E30Zone I picked these over the lager bodies from the GSXR 1000, they are too big for the engine. The 600’s should be about right.

The plan is to use tubing to connect the throttles to the manifold so that its possible change the lengths and see what the does to the power!

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Happy New Year 2009

Welcome to 2009 :o) I swear this year we’ll paint the car. Few other projects still on the cards such as exhaust valves, ITB’s adapted from a Suzuki GSXR 600, bonnet louvres and a bit of a change to the rear lines.

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Exhaust valve project

The exhaust on the car is a tad noisy when all 4 holes are open so we’ve been running around with one hole on each side plugged. We’ve been looking for a more elegant solution that would allow us to choose the volume.

<p>The starting point, Vauxhall Omega V6 2.5 throttle body, nice and cheap on ebay for £5 !</p>

The starting point, Vauxhall Omega V6 2.5 throttle body, nice and cheap on ebay for £5 !

<p>After chopping the throttle body in half with a hack saw and removing excess bits with an angle grinder it was time to turn it down on the lathe.</p>

After chopping the throttle body in half with a hack saw and removing excess bits with an angle grinder it was time to turn it down on the lathe.

<p>This is how it will work in the exhaust.</p>

This is how it will work in the exhaust.

<p>Here's one half down and the other half still with the rest of the metal on it.</p>

Here’s one half down and the other half still with the rest of the metal on it.

<p>Now both are cut out on the lathe.</p>

Now both are cut out on the lathe.

<p>Test fit with valves closed.</p>

Test fit with valves closed.

<p>Valve open!</p>

Valve open!

<p>Hold drilled through exhaust tip, throttle body metal fitted in test fitted.</p>

Hold drilled through exhaust tip, throttle body metal fitted in test fitted.

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1st Aniversary of SVA pass

I can’t believe its been a year and 2300 miles already!

It’s been little turbulent in that time:

  • Shortly after SVA pass we lost a wing stay (oops)
  • During December a complete disaster with the lower wishbone.
  • While off the road we completely rebuild the engine enlarging the capacity to 2.8ltrs.
  • In March we finally got the new and improved parts to put the car back on the road, decided to get light weight Carbon fibre wings to avoid issues with the (albeit stronger wing stays).
  • From then on it was a pretty uneventful summer with regards to mechanical issues.
  • We visited a number of kit car and other cars shows which was great to finally have the car there rather than just looking at everyone else’s!
  • Recently it pass its first MOT with one issue to sort out (handbrake cable loose), no problems with emissions on the rebuilt engine which was great.

The car is fun to drive now that it’s had most of its teething issues sorted out (still one or two such as the clutch and pedal box assembly need strengthening)

To come in 2009 a paint job (I know I keep saying it but I mean it this time)

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MOT

It’s been a year since the MOT it passed today! No problems at all with emissions on the rebuilt engine.

Only one small problem, the hand brake cable had slipped out of one of these things:

The solution was to mill a hole in one side through to the centre bore that the cable sits in. We then welded the handbrake cable into the bolt – its not going anywhere now!  Pictures to follow at some point.

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