lanfire

as above amazing detail

Garage19

Great build. Couple of tips for you that will make your ally welding easier.

First of all, get your foot pedal working. Ally will need lots of amps to start and will reduce right down as you go. It is VERY difficult if you have to run a static current through the weld procedure.

Second is you will find it easier if you set your joints up differently before welding. For an outside edge you need to set the sheet metal edge to edge so thet you have a 3mm vee with your 3mm material. You will get a stronger joint and it will also help you control the weld pool direction. So cut through the tacks, pop that last part off and take 3mm of material off each edge.

Red16

Thanks a lot


No problem, i'm happy people are enjoying reading it

Cheers, yeah all sorted, they were already gapped as they've been ran in the engine for a good few miles but worth a quick check.

How's your little car coming along?



Thanks for the tips, once the car is back on the road i'll give them a go! I want to have a good practice, get myself up to scratch.

If I could guarantee to have the time away from work, I would do a TIG welding course at college, but I wouldn't be able to make all the classes, it's a shame as I'd love to do it and would obviously benefit a lot.

Red16

Transmission shafts assembled, sealant applied to the lower engine casing and then the two were put together, bolts/washers fitted and torqued, then the generator, clutch, oil pump, water pump etc were fitted.

The sump is now finished and fitted.



The next things on the to do list are the starter motor and it's gears/covers, then the timing chain and cylinder head, it's getting there now.

NEEDFORSPEED

its not mate only need wheels and mapping aswel! once the kitchens finished il be back on with it, youl just be in good time for the weather and love the sump!

lanfire

looks really well that matey i wish i could weld

Red16

Here's a small update, I got the cylinder head and cams fitted, then timed it all up.



The old exhaust manifold wrap was very flakey and had started to fall off so I removed it to start again, but found the manifold had cracked in numerous places around the collector, doh! It's since been repaired and is ready to go, when I get some free time.

lanfire

good stuff mate, pluggin away !

Red16

I forgot to update this thread a while ago, the manifolds were fitted to the engine, engine put in the car, exhaust fitted and everything plumbed in.

Today the weather has been canny so I've had the car outside on the drive and got the engine running, nice to hear it again

scarnny

Good work mate, cant wait to see this up and runningagain.

scarnny

Any updates on this?

Red16

It is now

It's currently having an MBE 9A4 ECU fitted

http://www.sbdev.co.uk/Engine_Manage..._Technical.htm

an MBE 995 dash display

http://www.sbdev.co.uk/Engine_Manage...995/MBE995.htm

some extra sensors have been fitted to suit the ecu, a charging issue and a couple of wiring issues have been rectified and mapping has been pretty much completed.

Last time on the rollers at Daytuner it made 198bhp/101lbft @wheels on 8psi, speaking to Damien at Daytuner last week he said it's now doing 222bhp @wheels on 8psi and around 250bhp @wheels on 14psi, i'll have graphs and more info next week when I collect it.

Apart from the slight increase in power with the new ecu setup, the car starts on the button and runs smooth as can be, i've not witnessed it for myself yet but it pulls nicely from low down right through the revs/gears, can't wait to have it back home!

cozzy jeff

iTrader: (4)

Ben it was awesome fast when you took me out in it, it must be immense now.
Cant be much that can touch it mate.

scarnny

Great news mate we need some vids when you get it back.

What did you do with the clutch? As my brother has an R1 car the same as your and it keeps eating clutches.
It has the barnett coversion on it apart from plates and springs, just wondered what you are using as youve got much more power.

Cheers andy...

Red16

It certainly feels pokey

It's got a lock up clutch, which consists of an additional plate that goes on the end of the clutch with weighted arms mounted on pivots on that plate, as the engine revs up the weighted arms get thrown outwards and apply pressure to the clutch plates to combat clutch slip.

http://www.mtceng.com/products/mtc-p...ck-up-clutches

Red16

Today I took advantage of the nice weather and bonded mesh to the bonnet, here's the finished article



I also cut 1/3 off the bottom of the intercooler to allow more air to the radiator, when at steady throttle on hot days the water temp was reaching and settling out at 102 degrees C but the inlet charge air temp was 37 deg C max, around 5-7 degrees over ambient air temp, so it looks like the cooler is more than up to the job, hence deciding to reduce the size a little.

Here's how the intercooler currently looks

cozzy jeff

iTrader: (4)

nice work as usual mate

Red16

While the car was at Daytuner the following things were carried out,

Fuel injectors cleaned and tested.
A charging issue was rectified.
Power Commander and all associated wiring sensors removed.
MBE 9A4 ECU and required sensors installed and mapped.
MBE 995 dash display fitted to the steering wheel.
The Davies Craig water pump, radiator fan and turbo cooler fan were all wired up to an ECU output to allow them to all run according to temperature, the water pump also runs on after ECU turned off to aid turbo cooling.

Here's the MBE 995 dash display fitted to the steering wheel, it displays gear position, boost/vacuum pressure, coolant temperature, oil pressure, RPM, air charge temperature and battery voltage, it also has shift lights at the top and warning lights at the bottom.

Red16

Yesterday I got on with modifying the intercooler.

I made an aluminium plate to seal the bottom of each end tank, they were a snug fit so they pushed nicely into place, here's one in position



Welded up, not perfect welding but I'm happy my TIG welding is improving




The finished intercooler



With the mesh in the nose cone removed, you can see how much more radiator is now exposed



The car was built back up and taken for a test drive, it was a scorching hot day, water temps maxed at 90 deg C while driving and 92 deg C in short traffic jams, air charge temps were around the same as before maxing out at 39 deg C.

All in all I'm really happy with the days work!

Red16

Shortened the sump today, gained around 20-25mm of ground clearance, so bottoming out should hopefully be a thing of the past



Will get it fitted and tested out tomorrow if the weather improves.

DaveCrack

iTrader: (1)

Great to see how you keep constantly improving things on this car! Keep it coming and enjoy it.

Red16

Thanks Dave

Red16

Tested the new sump modifications out the other day, gave the car a good run out, everything appears well, no leaks, oil pressure looking good etc.

Unfortunately later on the car began smoking, mainly as it came on and off boost, the turbo was the most likely cause but further investigation was required.

A compression test of the engine showed 155psi on all four cylinders proved the engine was ok.

Took a boost pipe off and found oil inside, then took the K&N off the compressor housing and found oil in the inlet!



I've been in touch with Owen Developments today and I've bought a GT3071R core with metal bearing cage upgrade and a new ported compressor housing as my current on is too big, i'll install that core into my current turbine housing before fitting to the car.

scarnny

Whats causing this?

Rob_DOHC

iTrader: (4)

The car is obviously too awesome for the turbo to handle.

Great work mate, love looking through your pics!

Rob,

Red16

The turbo simply expired I presume, there is definite play in the bearings when you move the wheels/shaft.

I'll inspect the old turbo core when I've got the car back on the road.

Haha, cheers Rob.

Red16

Here's the new GT3071R turbo CHRA and ported compressor cover which arrived yesterday







Last night I removed the old turbo ready to strip and fit the turbine housing to this new core.

Red16

This afternoon I removed the turbine housing from my old turbo and gave it a clean up, here it is alongside the new GT3071R assembly



The up pipe from the old turbo compressor housing was cut off and cleaned up ready for welding to the new compressor housing.

Here's the new GT3071R, the old GT3076R and the up pipe



I didn't take anymore photos today, but in a nutshell the turbo has been refitted, along with the exhaust, coolant hoses and oil hoses after priming the turbo with oil.

Rob_DOHC

iTrader: (4)

How did you learn to TIG btw mate? Did you teach your self.

I can MIG averagely well and have been considering buying a TIG for ages now, just put off by the steep learning curve I keep reading about

Rob,

gingerturbo

iTrader: (2)

What a work of art, how I missed this build before I don't know

LIMITLESS

Good progress mate, looking very good

Red16

I'd done a little bit of oxy/acetylene welding in the past and always wanted to be a TIG whiz so bought an AC/DC setup and had a bash, I'm a long way off being a whiz but it seems to getting easier everytime, one day i'll be good at it, lol.

Cheers man

Thanks dude

Red16

Sorted out an external exhaust today to help with the issue of stinking of fumes after every drive of the car, test drive proved it works

It's a lot quieter at idle but not too different at full chat.

NEEDFORSPEED

looks ace that!

fezzajsy

iTrader: (9)

looking good

Rob_DOHC

iTrader: (4)

Thanks mate I think all the welding looks superb especially considering how quickly you seem to have picked it up!

What tig set did you buy? Make and model etc.

Thanks

Rob.

Red16

Cheers boys

This is the TIG welder I bought

http://www.r-techwelding.co.uk/weldi..._R-Tech_Tig201

Here's all their range of TIG welders

http://www.r-techwelding.co.uk/weldi...ent/Tig_Welder

Glenn_

iTrader: (1)

Looking good.Shame about the turbo spitting its dummy out.

Rob_DOHC

iTrader: (4)

Great thanks very much

Rob,

R-A-J

any updates on this beast?