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Jan 19, 2015 20:06:13 GMT
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Your fuel filter bracket will need some sort of strengthener to keep it from vibrating/cracking/falling off when in use. A simple piece of angle iron welded on the back will be sufficient, just be sure to tie it in at the mounting points as well otherwise you've gained no strength;)
Linking the combo of derv and aero body shell, interesting to see what kind of mileage you'll get.
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Steve
Posted a lot
Making progress in small, easy to handle chunks of awesome
Posts: 2,027
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Jan 19, 2015 20:33:36 GMT
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Now then.....where were we! OK so I had noticed a nasty looking bit of rot up in the n/s/f inner arch/floor area so after pulling up the carpet and carefully cutting a section of the sound-deadening surrounding the effected area I then took the grinder to rust and got rid... Then cut up a plate to cover said hole And buzzed it in followed by seam sealer and some paint luuuverly With that outta the way I made a start on the exhaust front pipe, will be going with a 2-2.5inch full length system but won't know if any silencers will be needed just yet so will try straight thru to start with and see what happens Among the many little jobs this weekend I fitted a pair of new track rod ends in prep for mot and make it easier to get the tracking set up. The car had been fitted with a genuine vaux alarm system with remote central locking facility when it was 6mths old...it no longer worked properly shame really. So that got pulled out properly and left me with a large hole in the drivers side of the dash where the plip receiver used to live....this gave me an idea! I gutted the internals, drilled a 12mm hole thru the centre and fitted a momentary switch for my glowplugs I prefer having control over how long they need to be heated so this will be hooked up to a decent relay with an ign 12v feed so they cant be messed around with when the keys aren't in it. I have been searching for a calibra/Cavalier gsi 4-spoke steering wheel for quite some time with no luck so I dug out my old mk3 sri wheel and gave it a good scrub... It's seen some mileage but will be much nicer to use than the standard Tigra item and will fill in nicely until a 4-spoke turns up More at the weekend....might even run....please Steve
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Last Edit: Jan 19, 2015 21:17:58 GMT by Steve
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Steve
Posted a lot
Making progress in small, easy to handle chunks of awesome
Posts: 2,027
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Jan 19, 2015 20:37:58 GMT
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Your fuel filter bracket will need some sort of strengthener to keep it from vibrating/cracking/falling off when in use. A simple piece of angle iron welded on the back will be sufficient, just be sure to tie it in at the mounting points as well otherwise you've gained no strength;) It's made out of the same thickness steel as the rh engine mount bud it won't be cracking anytime soon! But I take your point on strengthening as it does flex a little when undoing the filter so will prob revisit it at a later date
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Jan 19, 2015 20:52:36 GMT
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Your fuel filter bracket will need some sort of strengthener to keep it from vibrating/cracking/falling off when in use. A simple piece of angle iron welded on the back will be sufficient, just be sure to tie it in at the mounting points as well otherwise you've gained no strength;) It's made out of the same thickness steel as the rh engine mount bud it won't be cracking anytime soon! But I take your point on strengthening as it does flex a little when undoing the filter so will prob revisit it at a later date Even the thickest steel can succumb to cracking due to vibrations You'll probably be fine for a while then, but keep your eye on it, especially if you see it vibration badly whilst testing the engine. Since it's a diesel it won't spill flammable liquids everywhere if it were to fail so that's positive, it might even clean your engine! But still not something you'd want to happen.
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Jan 20, 2015 17:35:20 GMT
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hi, have you tried to gravity feed your pump ? i mean a little container on your bonnet directly to the filter or pump you change from petrol to diesel line problem maybe ?
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Steve
Posted a lot
Making progress in small, easy to handle chunks of awesome
Posts: 2,027
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Jan 20, 2015 17:56:59 GMT
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hi, have you tried to gravity feed your pump ? i mean a little container on your bonnet directly to the filter or pump you change from petrol to diesel line problem maybe ? The fuel system is bled thoroughly now with no issues regarding flow as we found out Sunday. Its firing, producing exhaust smoke in the process just not spinning over fast enough to get all four cyls firing properly...
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Jan 20, 2015 18:47:23 GMT
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hi, have you tried to gravity feed your pump ? i mean a little container on your bonnet directly to the filter or pump you change from petrol to diesel line problem maybe ? The fuel system is bled thoroughly now with no issues regarding flow as we found out Sunday. Its firing, producing exhaust smoke in the process just not spinning over fast enough to get all four cyls firing properly... i don't now it than. engine mileage ? lose idea getting injectors pop test or just as you say giving it a tow than you now without spending money.
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dggp
Part of things
Posts: 135
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Jan 20, 2015 19:12:19 GMT
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random question but have you got a copper washer on the banjo fitting for the fuel filter, can't tell in the pic.
I serviced one and it dropped off without me noticing... couldn't start it for love nor money despite having fuel at the injectors and such due to it sucking in air
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Rich
Club Retro Rides Member
Posts: 6,248
Club RR Member Number: 160
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Jan 20, 2015 21:44:13 GMT
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The fuel system is bled thoroughly now with no issues regarding flow as we found out Sunday. Its firing, producing exhaust smoke in the process just not spinning over fast enough to get all four cyls firing properly... i don't now it than. engine mileage ? lose idea getting injectors pop test or just as you say giving it a tow than you now without spending money. It'll go with a tow. We nearly burned the starter out on our kubota 2 cylinder diesel getting it running after a year and a half on its side on a pallet and that's an engine you can spin over by hand! Just wants a bit of speed for that initial start up.
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Jan 21, 2015 19:50:55 GMT
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i don't now it than. engine mileage ? lose idea getting injectors pop test or just as you say giving it a tow than you now without spending money. It'll go with a tow. We nearly burned the starter out on our kubota 2 cylinder diesel getting it running after a year and a half on its side on a pallet and that's an engine you can spin over by hand! Just wants a bit of speed for that initial start up. interesting to now I'm putting a xud9 in a berlingo shortly that lay for 2 year.
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Steve
Posted a lot
Making progress in small, easy to handle chunks of awesome
Posts: 2,027
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Jan 24, 2015 20:56:54 GMT
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Been spending an hour or so every night this week finishing up a few bits here and there, got it back down on its wheels and filled it up with coolant along with finishing the glowplug wiring so that now works from inside the car. Tried to fit my nice old mk3 steering wheel only to find that airbag-equipped cars have a different column cowling compared to the older non-bag models so need to sort one of those at some point and need to unplug the airbag ecu so its legit for the upcoming mot sideskirts went back on today and a few bits of trim back inside as the car is going off somewhere tomorrow.....will update you as to what's happening later Have a pic from the last night's tinkerings and as promised a pic of the stealthy intercooler install Oh...And found one more steel wheel so just need another two then they can go off for some banding More soon Steve
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Last Edit: Jan 24, 2015 20:57:44 GMT by Steve
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Steve
Posted a lot
Making progress in small, easy to handle chunks of awesome
Posts: 2,027
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Jan 25, 2015 19:09:56 GMT
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We gotta heartbeat
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Steve
Posted a lot
Making progress in small, easy to handle chunks of awesome
Posts: 2,027
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Jan 25, 2015 20:14:39 GMT
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So as you can tell our tow start worked, after a few yards it coughed into life and drove back under its own steam...or in this case....smoke After a tweak to the idle screw it settled down to a nice 900rpm idle and has fired up twice since on the key so I think we can call this a success! Still need to finish intercooler-to-turbo piping and finish the exhaust so it actually exits to the exterior of the vehicle then it's mot time feeling good. After the mornings win I got on with a few little tasks starting with changing the tacho for the correct diesel item. Take one set of standard Tigra instruments... *sorry for sideways pic...bloody phone* Then remove outer front surround and screen, just a few clips on the outer edge to release and you should end up with something like this... The tacho is secured with 3 torx screws, remove these then gently pull the front face of the unit till the contacts on its circuitboard release from the main casing then simply replace with diesel item... Like so Then it's simply reassemble in reverse of removal and job done! Will quite possibly pull it all apart again at some point to change the needle over but it doesn't bother me so may not.... Cavalier steering wheel went in, had to do a small amount of wiring as the horn buttons on the original wheel worked thru the airbag rotary coupling behind the wheel as opposed to earlier vehicles which take a live via a pin that rubs on the back of the wheel...mine was fitted with it but never wired up so nice simple job no column cowling at present as the airbag type is too deep so need to find a tidy one, prob at same time as I go hunting for an engine cooling fan. I also managed to spend several hours just trying to change the bulbs that illuminate the heater controls...what an ar$e of a job! More possibly tomorrow as my auxiliary gauges need to be mounted... Steve
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Last Edit: Jan 25, 2015 20:17:16 GMT by Steve
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Colonelk
Posted a lot
Posts: 3,740
Club RR Member Number: 83
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Jan 25, 2015 20:27:42 GMT
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Yes mate! Glad its running now What else before its on the road?
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Steve
Posted a lot
Making progress in small, easy to handle chunks of awesome
Posts: 2,027
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Jan 25, 2015 20:37:06 GMT
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Yes mate! Glad its running now What else before its on the road? Engine bay pipework, zorst then wash and mot it's pretty much done....
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craig1010cc
Club Retro Rides Member
Posts: 2,993
Club RR Member Number: 35
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Jan 26, 2015 10:43:41 GMT
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Cracking progress Steve
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Jan 26, 2015 12:34:45 GMT
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Nice oddball conversion (in the nicest possible way). Fast turnaround - well done.
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Speedle
Posted a lot
Need a Country Rock band in the Hampshire Area? https://www.facebook.com/DirtRoadDiaryUK
Posts: 2,221
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Jan 26, 2015 15:37:29 GMT
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great conversion sir very cool!
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Jan 26, 2015 17:16:48 GMT
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That's fantastic! Well done. Seemed to go by quickly!
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Steve
Posted a lot
Making progress in small, easy to handle chunks of awesome
Posts: 2,027
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Feb 18, 2015 10:21:51 GMT
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Bit slow on updating this for which I apologise... Following on, I sat in the car trying to work out where best to put my boost & egt gauges...the sensible idea would have been to pillar mount them but that just screams boy racer to me and that ain't how I roll so pondered putting them in place of where the ashtray is but would have ended up spending far too much time on a tidy install so what about on top of the mfd(clock to you and I)....nope looked horrid and basically cut my field of vision down too much so I compromised and went left of it Not in my way too much and still easy to read without having to turn away from the road so that'll do I deliberately mounted it so it's only screwed into a removable panel so if I change my plans I can replace the panel and it look good as new again. Will be pulling it apart again soon anyway as I will have to change the boost gauge for a higher reading one The probe for the egt gauge is yet to be fitted as I kinda ordered it late and had already fitted the turbo & manifold up so couldn't drill it, I will hopefully be obtaining a 1.7 item soon so will drill it before it goes together but for now the probe is coiled up and put out of the way in the engine bay. I just have to remember not to keep my foot down for long periods to avoid melting the motor one disadvantage with tuning diesels that nobody thinks about! Intercooler pipes were kinda finished, the RH pipe was tig'd up for me so that's nice and neat but the LH was less so...I will redo this mess at a later date but for now it works. The turbo cold-side inlet & outlet are soooo tiny that I had to hunt for reducer silicone pipes in order to connect everything up, the result is not pretty in terms of flow but since this setup is not likely to be here long I won't lose sleep over it Boost controller was purchased and fitted...wound it it just a tad too much...but unsurprisingly I haven't remedied that it pulls like a train!! Fuel screw has been tweaked so as to only produce a small cloud when foot flat to the floor but runs clean when driving normally...it's making between 20-25psi of boost initially but trails off a little after a few secs which I'm quite happy with it's quite a handful going up thru the gears as it torquesteers alot...should have expected that really but it caught me off guard the first time I really gave it a bootfull! Ha ha The exhaust was fabbed up in one afternoon but I don't seem to have took any pics it's 2.25inch with a flexy up front, straight thru centre section with a cherrybomb-esq resonator box out back and a simple tailpipe....not flashy in anyway but that will change soon. It's not overly loud, does drone a little but thanks to excellent sound deadening it doesn't annoy too much and barks nicely when on boost/higher rpm...very pleased with the overall package as it certainly gets pedestrians scratching their heads as to where the growling derv noise is coming from With the car now being in a state it could be mot'd I booked it in.....where it promptly failed on a rust hole I didn't see que me spending an evening repairing said hole outside....in the dark...it was a cold night Covered the whole area in shultz after so shouldn't bother anyone for awhile. Retested fine and also had them setup the wheel alignment as it was toeing out really badly and pulling every which way it liked especially over bumps...all good now happy to report that the eps-manual racks when not power assisted are quite nice to use, a bit heavy when parking but not too bad on the move and very precise with only small amounts of travel needed for sharp cornering...me likey :Do So with all the important stuff out of the way it commenced use wherever I could and aside from the alternator attempting a break for freedom and a sticky no.1 injector causing a bit of rough running when stone cold it's been dead reliable and racked up 400-450miles easily! I celebrated by giving the thing a wash... Which highlighted just how awful the paintwork really is...stonechips everywhere, rust coming thru in some odd places and a large covering of powdered metal from someone grinding over it nearby(not me I may add)which is turning into rust spots gonna make an attempt at tidying it up best I can but if all else fails....full colour change will be on the cards More soon Steve
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