DaveCrack

iTrader: (1)

Can't wait to see this thing finished and on the road!!!

Red16

Cheers for the positive comments lads

Just for you you nosey git... the hole in the bottom of the petrol tank is 62mm diameter.


Been down to Mac#1 this morning with a mate to drop of some parts off to be modified to suit his Mac Type 9R... while we were there I collected some of the switches which were on back order, still waiting on two but I can still progress the dash panel in the mean time.

Once home I went in the garage and welded on the clamp on exhaust fitting to the end of the silencer



then welded a bracket to the end of the silencer to allow it to be supported from above by a rose jointed linkage.



The silencer was then wrapped in Thermo Tec Generation II Copper Heat Wrap



and then given a couple of coats of Thermo Tec High Heat paint.



That's all for now folks.

kjc300

iTrader: (1)

lolol, cheers for that


I need one much bigger than that though but it gave me the o-ring idea in the first place for a project I have

cozzy jeff

iTrader: (4)

nice work there matey,ill pop round next week to drop your socket off.

Red16

No worries, the resto section is always a good place to grab ideas.

Well there may be a bit more progress by the time you get round, I've got the bug again

Red16

I finally got round to bolting the exhaust on with some new gaskets, which allowed me to cut the hole in the side panel for the last time.

This is how it looks with a 3" inwardly rolled tailpipe



But i didn't like it so cut it to have the slash cut look... much better



Here's a shot of the finished exhaust, just waiting on the rose joints being delivered then it will be supported/hung at the end of the silencer.



The dash panel rested in position



Hole cut for the steering column



Marked out and cut the holes for the switches, then progressed cutting the hole for the clocks.



Sort of how the finished article will look, after the IVA i'll be adding some guages (boost/oil temp/charge air temp) below the standard instrument cluster.



I'm not happy with the cutting of the dash panel around the clocks, it will need to be addressed in one way or another as it looks poor!

escort1989uk

dash looks good keep the updates coming

Glenn_

iTrader: (1)

Nice little update.I like the way the clocks are too.I think the slash cut exhaust looks really well too.

cozzy jeff

iTrader: (4)

cracking on now matey,love the exhaust.

Red16

Thought people would prefer the exhaust with a slash cut

Here's a tiny update from today, not done much other than collect this header tank from the post office



then decided where the fuel pressure regulator was going to be fitted, measured up and ordered the braided fuel lines and fittings needed to complete the fuel side of things

Not long at all til it's ready to be wired up and then fired up!

-beefy-

iTrader: (6)

cozzy jeff

iTrader: (4)

whos the bufty now mate?

Red16

Bugger off!!

Red16

Just spotted this and I want one... it's class

It's a shame money needs spending elsewhere at the moment, i'll have to treat myself when the cars on the road!

cozzy jeff

iTrader: (4)

love the lid mate,will you be wearing one on the road or just on track?

Red16

I'll probably not bother with one around the doors but when I go for a play over the lakes etc i'll shove one on, i reckon a stone catching you on the bonce after being kicked up by a bike in front would bring tears to your eyes or cave your skull in!

COLEYST200

iTrader: (3)

very nice work mate will the motor be ok with that size turbo

Red16

Running around 300bhp at well under 1bar with forged internals etc it should be ok but with the boost wound up and the possibility of 450bhp+ it may be a different story, will just have to wait and see.

This is the spec below, although that kit uses the gt3071r turbo.

http://www.bigccracing.com/shop/prod...0&source=thumb

RS20004x4

yeah even a wasp in the face at speed stings, my mates got a westy xtr and we dont normally wear lids when just local but do on a longer runs.

great project btw, looks fantastic so far, would love to build one, maybe next year.

Red16

This afternoon I had another look at the dash, it was decided that it definitely needed some remedial work because it looked hideous! as you can see below



So I dismantled the clocks, then marked out and cut the new orifice into the dash



The rear of the clocks fits through the dash from behind like so



and when assembled the clocks look like this... much better



It definitely would have looked better with the speedo face flush with the dash panel as per the previous way if the cutting had been neat but this way looks much better than the previous with untidy cutting. I may redo the dash at a later date.



The semi complete dash back on the car



Handbrake lever fitted



Aeromotive fuel pressure regulator mounted, waiting for the fuel lines to be delivered.

cozzy jeff

iTrader: (4)

looking good mate,i think you made the right choice changing the clocks,look much better.are you getting your hoses off jimmy?

Matt Baxter

iTrader: (37)

looking the part wont be long now eh

Ginger Will

Looks mint. I think the clocks look better like that.

Red16

Cheers... i'm going for Aeroquip hose and fittings, will be making them up to suit myself in the garage.

Nope, not long at all really... still hoping to have it finished April and on the road in May.

I have to admit, the way they are now is growing on me.

Red16

I've been playing outside today while the weather was reasonably mild, I got the springs rearranged on the coilovers, so the 225lb are now on the fronts and the 175lb on the rears, which was a job I had been putting off for ages, nice to get it ticked off the list.

Then the bonnet pins were fitted



From the rear of the Aerocatch you can see how they meet with the pins.
I still need to fit the rubber bushes over the top of the pins, the bonnet is clamped down onto these holding it securely.



While the car was outside and with the newly fixed bonnet and nose cone on, I decided to take some more photos









Seeing it like this, I had a really big grin on my face

This is the plan for the cooling system, replacing the expansion tank with a header tank.

GaryHurn

iTrader: (1)

looks very cool love the colour

cozzy jeff

iTrader: (4)

cool as fuck mate your doing a cracking job.

jon_ross

iTrader: (1)

just sat and read all 7 pages and ive got to say this project is fooking awsome, i love it.

theres a guy in polegate were i live with an orange one of these and that has the same engine as yours but without the turbo and ive seen it just ripping past me down the bypass and its scaryly quick, i mean like next to you , blink, and its then gone so fuck knows what yours is gunna go like!!!!!!! 0 to 60 sub 2 secs???

RSricRS

iTrader: (2)

Wicked...!

Sp3no

iTrader: (1)

Great project!! Which type of welder have you used for your exhaust fabrication? Thanks

Red16

Glad you lads are enjoying reading the thread... thanks for the kind words

The exhaust was gas welded with Oxy/Acetylene using 1.6mm 316 stainless steel rods.

Red16

I didn't do anything on the car yesterday due to feeling a bit unwell but I did manage to take delivery of some parcels...

First off some rose joints and misalignment spacers for the exhaust support hanger.



If you've been reading the thread you'll remember the standard oil/water heat exchanger has been removed to make space for the turbo, meaning no oil cooling at all, so I've been doing a bit of research and I have been unable to find an upgraded oil cooler kit for a Kawasaki ZX10R.

The Kawasaki oil filter thread is M20x1.5 and the oil filter seal is I.D. 54mm and O.D. 62mm.

I found on ebay a Mocal sandwich plate with built in thermostat intended for Peugeot 106/206/306 GTI, the dimensions looked suitable so I ordered it.

Here it is...



The oil filter screws on nicely and seals nicely against the sandwich plate, result... well it will be if it fits to the remote oil filter mount, but there doesn't look to be any reasons why it will not.

Red16

Another package was delivered this afternoon, some -6 braided fuel hose and fittings

cozzy jeff

iTrader: (4)

where did you end up getting your hose from mate,is it teflon lined?

Red16

It's from ebay Jeff, it's nitrile lined not teflon, I went with the nitrile as I thought it would be easier to work with.

Loosely fitted some parts today, here's how the fuel hoses and filter fit between the regulator and rail.



and with the inlet in place



Cut to length and then made up the hoses, here's the Bosch 044 pump outlet



Return hose to tank, it fits a lot better when routed and fastened down correctly



and finally the feed/return hoses connected to the fuel pressure regulator.



I'll get round to fastening the hoses securely to the car tomorrow.

cozzy jeff

iTrader: (4)

nice work mate,really tidy.how'd you find making up the fittings,a little fiddly?

Red16

Cheers kidda, they were easy enough to assemble really, it's definitely best to cut the hose with an angle grinder with a slitting disc, much better than a hacksaw.

I've just ordered some Aeroquip socketless push on hose and fittings to plumb in the remote oil filter and oil cooler... hopefully the oil cooler I ordered the other day will turn up in the post tomorrow

super-ron

all looking fantastic, i like alot is it only a 1 ended fuel rail on these then? not seen the inlet and FPR on the same end before?

Red16

Yeah the rail only has a feed to it, it enters the rail in the centre, there's no return directly from the rail, only from the regulator, but it works exactly the same.

Red16

Today I tidied up the fuel hoses and secured them to the chassis







and took delivery of a non return valve to use on the breather outlet of the petrol tank