Hi Sy looking good man!

But the charge carrier hit the bonnet? How come? I thought it was specialy designed to fit in one time?

But you managed to get it fit by trimming the strenthening beam?
But what is the strenthening beam?

 

The beam above is cut a little then get some thin hose, split it down the middle and put it on where the cut was.

This is how Lee has done it.

JAmes

 

 

So it is just an 'simple' cut in the bonnet? But it is necessary right?

 

Yup a must. Should have no affect on the bonnet strength at all and if done correctly is fine and tidy.

JAmes

 

I think i'm going to take the whole section out and have the bonnet louvred to draw heat from the charge carrier.

 

How much heat will it draw though? Theres the plastic around it insulating it pretty well i imagine.

Your best option would be to get the exhaust manifold ceramic coated or use that wrapping stuff that keeps heat in.

You have the advantage that the air is going to come in and then go right through the turbo. The way that Lee does it means that there is a pipe going over the manifold which i expect makes it pick up a bit of heat once the pipe itself is heated up, but this is a must as we have an air filter. I'm trying to think of a neat and tidy way of stopping this and so reducing intake temps.

My mates just put new ceramic coated headers on his car so i'm gonna get a look at the change in intake temps to see if its worthwhile looking into ceramic coating.

JAmes

 

Having the vents at the high point will mean air passing up and over the bonnet will vacuum hot air which has risen up the engine bay and is trapped near the chargecarrier out of the bay. Thats the theory anyway as the heat isnt just generated from the turbo but the whole engine and its a fair bit of heat.

 

Yeah i know. It should relive the overall heat build up but with any luck your charge carrier will be insulated from this due to the plastic its a cool way of doing it.

Also as your not using the car every day, ditch the weather strip. Hopefully let some of the heat out this way too.

What kinda luvers you gonna go for? any sort of style or pattern? I do like Luvers, they look mechanical like old bentlys.

 

does the filter have to go near the battery? can it not be fed down by the alternator somewhere, its colder there too!

 

I dont think it can go anywhere on that side of the engine bay due to the lack of room there. Thats the problem with the Ka

Bonnet chewed up. I tried to removed a small section of metal but my tinsnips must have been for right handed people.

The whole lot came off



The bread test indicated it was a good fit

 

Hi Sy looking good! Now for a test drive?

BTW how did you do that with your bonnet? With a Dremel orso and a bit of welding?

 

take it that mistake hasn't affected things too much then!? just gives you more space!
how many more days to go now? looks amazing! is it going to donnington?
dan

 

i used a set of tinsnips to cut the bonnet (like scissors for metal) cos im left handed it wouldnt cut well though so i just took the whole lot off which im more than happy with as i want it louvred anyway so i just need to tidy the underside up at some point.

I say this every week these days but im hoping to test drive this weekend and mot monday or tuesday.

Not sure if ill be taking it to Donny but if i do get the MOT sorted there is a redline photoshoot for cruisinuk at leek on the saturday i may pop along too. Will have to see how things go.

 

hmm leek isnt all that far away fom me! thats round stoke way isnt it

guessin it depends on the weather as to wether it goes to donny or not then?

i tried to upload my photos on the computer but its not lettin me for some reason ill have to keep them all on the mmc card till i can get it to work then ill post loads of them up at once!

your site is gettin better now too i must say!

 

Your at Cannock aint you? I think its about 40-50mins from you. If im going and you can make it for a nosey it would be cool. Ill let you know how things go

Not too fussed about the weather for Donny as its always raining and cold but its just a bit of a shitty meet lol.

Look forward to the pics.

 

yeah im only in cannock so not far really, what date is that then is it the 16th? if so its the big mids 10 cruise at birmingham wheels too, Ł5 entry but have lots of confirmed mags!
can get you more info on this if you want!
sounds all good! ill PM my mob no if you want then if i cant get on here you can always let me know how it goes and wether you can come out to play!

Dan

 

have you thought about jackin the back of the bonnet up at all? ive seen a few ERST boys with this done for cooling, may give extra clearance too

 

Did try jacking up 10mm but it made the catching worse due to the angle of the bonnet. Looks a bit naff though i think. Not as good as lourvres

 

worth a go all the same i spose!

 

bread test quality idea

 

I think a raised bonnet is shite looking too, on any car.

Anyway, looking good Sy with the new charge carrier on...

 

first time i saw one i thought car had been in a shunt

 

Im not suprised mate, thats shows how much out of place they look.

 

I like it on some series 2's

Doesnt look right on the Ka

I had yet more problems today Battery died as car wasn't holding any charge so spent the day sorting that out. A new alternator later and the problem still wasn't sorted. I tracked it down to bad earths on the alternator mounting bracket cos of the powdercoating Ah well i have bling new alternator now.

I drove her on the roads for the first time today, bit smokey and didnt run to great but ran and stopped, boosted nicely and fluttered when i let of the accelerator. Good stuff! Just need to find out why bits fall off it Not going to be ready for next weekend though which im gutted about

All new to me though having never even driven a turbo car so i don't know if its any good or not. Another step forwards though. Hopefully have a video of it on the road tomorrow

 

good to see its running good luck sorting it 100%

 

Some video footage of the ka on the move

Clicky Here

Very chuffed nothing broke and produces just under 1 bar of boost nicely but i didnt give it too much go.

 

Looking and sounding good Sy! When do you update your site?

 

what parts fell off the car then the first time you ran it? take it there wasnt much fixing needed to be back out for another run for the video though!
definately no chance of this weekend then?

dan

 

A jubilee clip came off and intercooler was hanging off dragging down the road - good job i am getting a new one before the feature lol Easily sorted and fitted back on.

Im not sure about this weekend yet, id love to be able to bring it along so im gonna work my ass off on it and see how it goes. I feel a lot more confident now i have driven it a little.

I just have to fit the bumpers, put the proper mix of coolant in and wire the fan to the thermo switch. Obviously its not show condition at the moment though Ill see how it goes.

Website updates coming soon now i have found the disc with all my pics from the last year on there which had gone missing

 

hope it all goes to plan and its ok to drive at the weekend!
cant wait to see it!
what intercoolerr you getting for it?
wanna sell me your old one :P

 

Same style and shape but all ally and silver rather than black at the moment. I will be looking to sell the old one, isnt in the best nick as its got a few dings in it but performs okay. Ill let you know when im selling it.

 

Yes, maybe you've got some pictures of the intercooler? I might be interested!

 

 

Thats the best post i've ever seen!!

Kavid, the first page of this topic.

Good to see its running Sy, and glad you've got a few teething problems too

JAmes

 

just found a couple more too water leak (small) and a drip of oil coming from the gearbox

 

Yes, but i meant the intercooler how it looks now!

Sy, is the gearbox leaking by the welding orso?

 

where are the leaks coming from then? is it just loose hoses for the water?
gearbox sounds worrying tho
hope it gets sorted soon!

Dan

 

Water leak is from the rad hose as the hose is a tight fit in the cradle, will need to just tighten the clamp.

Oil is coming from the sumpgasket or the crank oil seal. That was one drip of oil but its still annoyed me.

Nothing to do with the welding as that just the bellhousing.

 

Which side is the crank oil seal? dont remember replacing that when i did bottom end! best check really hadnt i! is it flywheel end or oil pump side?
take it you mean the bottom hose on the rad? theyre all awkard!

Dan