Well I’ve had a busy few non car days, but I’m getting back on track now. Some more parts arrived through the post, I’ve now got my Megasquirt relay board and connection cable. My fuel lines have arrived and all of the connections, it should be super duper neat, just the way I like it
I’ve got some more done on the radiator today, the pipes are almost in they just need painting and connecting up. I’ve tried to remove as many of the joins as possible, the last pipes had 10 or more joins each! The new ones should have no more than 5 joins, less places to leak!
Removing the fuel tank to get to the master cylinder and rad pipes ( the master is to be changed to a 0.7” for the disk setup)
The tank removed, its all so clean and nice down there! The pipes for the rad will go through the small flat on the opposite side to the master cylinders.
Here is where the rad pipes go up through the rear seat, nice and neat again, the rear seat squab will be able to go back on top, just no one is allowed to sit on it!
This is where the rad pipes go through the front bulkhead, they will be protected through the sharp hole edges.
These are the new aluminium pipes that go through the rear bulkhead, again less joins so less chance of leaks.
Old radiator out, quite a large bit of kit!
New header tank put in position but not bolted in, this will be re-painted. The old fan will be removed aswell, should free up a couple of HP.
Then as a treat after the radiator work I mocked up the intercooler, it fits like a dream at the top of the engine bay, with plenty of room to get to the header tank. All of the pipes line up beautifully, I cant wait!
Tool of the day today was the ratchet pipe cutter, made it nice and easy to cut my 1” bore rubber radiator pipe, hot knife through butter!
Tomorrow I shall get the radiator in properly, attach up all the pipes and then make the shroud to direct the air. The master cylinder will be swapped for the 0.7” one, and the intercooler mounts will be fabbed up hopefully.
I was a bit pessimistic the other day about getting it done, i now think that as long as all the parts arrive on time the itll be running. If the inlet manifold dosent work out then i can still run it with the blower but no injection, using the metro turbo carb and some high octane fuel. I really hope the injection is on though, would make my life a lot easier!
Thats what i was thinking, baby 911! There will be a small ducktail spoiler to draught the air into the 'cooler, and then ducting to the low pressure area behind the wing. Hopefully this will encourage the air from the high pressure around the rear window through the 'cooler.
I'm enjoying the freedom to work on my car for a while, ive been stuck without a car at uni for a long time, so i think i deserve it
Well today has gone quite well, the radiator is now in and mounted, and the cowling is 90% done. This should direct the air in the correctly, from high to low pressure, hopefully taking sufficient heat with it!
I started by mounting the radiator, I’ve moved it slightly so that it is more upright, this way it is easier to mount and direct air to. Oh and it is a puller fan, so the air is going in the correct direction!
Not so much of the core is directly in contact with the flow stream, but it should be fine
For the shroud I started with some sheet ally
Measured up the space for it at 50cm x 50cm, then I started to cut lots of bits off so it fits the space
And I ended up with this –
The side sheets were a little more tricky, as they had a specific shape to now fit into. A template was created, and trimmed to fit the space, this was then transferred to the ally sheet and tabs added for joining purposes
Sheet with tabs
The other side will be very similar but with a few subtle differences, itll all be screwed together tomorrow.
My tool of the day has got to be my falcon nibbler, British made tools FTW!
Tomorrow I really will attack the intercooler mounts and that master cylinder is also going to get it good
For now though I’m going to Goodwood horsey racing! Free booze so I cant complain
Day 11 – welcome to James Hill’s “how to fix a car until its borked!”
Well the horses were fun, I won a fiver so cant complain!
This is a bit of a long post, I do apologise, if people want me to slim them down I will.
Today started out a little bit frustrating, as I am not happy with the way the radiator cowling is turning out, the back piece is fine, it’s the side plates that are annoying me. I think I may make them in plastic, as this is much easier to manipulate and form to the body shape.
After getting frustrated for a while I decided to give my self another job, take my mind off the radiator for a bit and move on to the intercooler mount. This is going to be attached rigidly to the body, not the engine. It is going to be attached to the rear bulkhead where the coil currently is, the engine mount on the rear cross member, and the side panel where the boost strut currently is. This would hold it in the X, Y, and Z planes, and so it should be jolly secure.
I started with the bottom mount that is going on the rear cross member, I made this from 4mm steel plate, should be strong enough! I marked it out on the steel using a scribe, rule, engineer’s square, and centre punch.
I then drilled the holes for the bolts and the inside of the inner curve
I then cut it out using a hacksaw, this is very good way to get jolly hot on a summers day!
Then it was filed by hand for about an hour, this is a jolly good way to get very very very hot on a sunny summers day!
It fits like a dream, and shouldn’t have and fatigue problems being 4mm thick. This will have two tubes welded to the outer edge that will support the intercooler.
After that little success I decided to move onto another mount for the intercooler, this is the one on the outside edge, mounting to the bonnet stay.
I started with a card template that allowed me to tune the angle that the intercooler will be mounted at.
This folded into this shape
I then found some 1.5mm stainless sheet, this was my parents kick board in the kitchen! So now unused, I cut it up to the shape of the template
I then folded it just like the card, and welded the contacting edges, the finished product will have a hole put into the side that will mount the intercooler flange.
I then fitted the 0.7” master cylinder to the car, this is a relatively easy jobthat took all of 1/2hr. Piffling!
I then got a call from the machine shop that are making some modifications to my parts, they were finished with one small complication!
The pulleys were amazingly finished to a very high standard, and I cant wait to get it all fitted!
Heres the shop, only wee, but very capable
Here are the two pulleys and the trigger wheel
The problem came with the flange for the supercharger, the program for the CNC mill had a small and un-noticed glitch that meant the cutter decided to head right through the plate! Fortunately this was solved with a piece of steel cut so precisely that you would never know it happened! I duly TIG’ed this section into the flange so it’s as good as new
The section TIG’ed into the main flange
And the whole blower setup
That’s all for today guys and gals, its been quite a productive one and I'm happy, that’s all that counts! Tomorrow I shall move on with the intercooler mount, hopefully have this finished and ready to spray up. I will also strip the paint from the intercooler end tanks, as it’s a little worse for wear. I think I will also start the supercharger mount, as once these two are on I can start to think about the inlet and fuel system.
Oh forgot to say, the engineers that did the modifications on the pulleys for me were very good, they will take on pretty much any job, and are very reasonably priced. They started out doing engine work, so are very experienced in engine machineing etc.
Its very refreshing to see someone using hand tools to cut and finish parts, especially when its 4mm thick steel!!!! absolutely blinding work! The pulley looks awesome, as does the rest of the build, inspirational!!!