bob le routier

Hello guys !

First thread from me !

I'm trying to set a hart plenum on my 2WD LHD Sapphire.

I got a problem about the gap between the plenum and the ABS unit.







On LHD, we have a plate to fin. Behind the plate, we have the 6 ABS valves and about 100 bar of brake fluid pressure. I think the modification should be done properly.

The only thread giving a solution is this one:

https://passionford.com/forum/restor...00-hp-4x4.html




I would like to know if someone know people using to do such a plate.

Thank you !

Regards ! Romain

Caddyshack

Hi and welcome.
Do you need to remove the ABS unit to get the hart in there? If not surely you can add the nut to the thread and then add the plenum? (seems to simple so assume you cannot)

If not I think you need to remove the thread and have it drilled and tapped for a bolt to go in - surely that would give you the room.

OR I wonder if Mark Shead could tell us if it would have a dramatic negative affect to machine a dimple in to the inlet to allow clearance, maybe have a few mill skimmed off the flange face of the inlet where it meets the head as well?

Caddyshack

You can probably move the whole pedal box a few mil as well but that would mean ovalling the holes and somehow re-sealing the bulkhead

bob le routier

Why not, it may be an option.


I tried by removing everything between the plenum and the cylinderhead including all the studs. I haven't removed the ABS unit. On the two first pics, the plenum is set, the only question is about the room to put all the studs in the cylinderhead threads.

If I am worried about the clearance it's about the engine movements. As you can see, I got about 2mm of clearance.


I am afraid about fragilizing the plenum. For LHD, Oppliger made a plenum with a thin bottom:





Few pics of my car:

Caddyshack

Yes, I can see that the engine movement could knock it and break something, you do not want to ruin either. I am sure a good fabricator could make one of those covers for you.

Moving the pedal box 5/10 mm might be the easiest and cheapest option and easily reversed.

nixon_2wd

Alternatively you can get a RHD brake booster or one from LHD Escort Cosworth (harder to come by). They provide much more clearance as they dont have that big block on the side.

bob le routier

That's why a created this thread, to know if someone have the habit to mille this cover with the good blueprint.


Yes, I have to check the clearance on the other side and how the brake lines move.



Good idea ! I will try to find pics about ABS bloc from LHD escort and 4x4 sapphire to see the differences. I supposed that the block valve is separeted from the whole ABS unit like with RHD ABS block.

grcossie

bob le routier

Thanks, is it an escort cos LHD braking system ?

bob le routier

I can see that the Jaguar XJS is equiped with a similar TEVES ATE MK2 ABS system.

I can also see they get a remplacement valve block with a very thin cover:

https://www.jagroverland.com/abs-mod...1475-open-box/

The cover seems to retain the valves:

https://www.jaguarforums.com/forum/x...l-left-113913/

stevieturbo

I presume that is a stud in the first photo ?

Just remove it and fit a shallow head bolt as per the lower fastener in the photo ? Or just shorten the threads of the stud and use a half nut.

And ensure good strong engine mounts.

or as others said, just move it a little to the side, even a small spacer giving the unit a small angle would not hurt how it operates, but would give you additional clearance at the manifold side.

bob le routier

I will manage about stud and nuts

Yes, it seems to be a good option to increase clearance.

The kind of plate I would like to find:

Volvo 480:


Remplacement block for Jaguar XJS:

bob le routier

Some niews before brexit !

Some cars with Teves Mk2 ABS have a thiner plate :





In place:



Wiith the manifold and studes cuted:











Modification on the steering fluid tank:





Home made linkage between the plenum and the engine silentblock





The hose between the intercooler and the throttle body. I think I will modify the outlet of the intercooler to have them aligned:



The throttle cable whitch is too long:





A wide view of the result:









With the throttle cable from Escort mk2 RS2000 with the two ball ends. Its length si 750mm long. It is not perfect but better than the 1060mm cable from LHD Cosworth. I tryed with a cable from Escort mk2 which is 575mm long, but it's too short:

Caddyshack

Looks good. Very clean too.