416 replies to this topic

[KTS]

slowly chipping away at the to do list....

 

remote gear assembly re-fit should have been a nice easy job, but as one of the roll-pins got jammed halfway in it turned into a bit of a struggle to extract it; i was getting to the point of thinking about welding a nut to the end of it so i had something to pull on, but fortunately came up with a different solution

 

 

sorted out the nodiz loom to set the cable runs to the right lengths

 

 

trimmed the brake duct i'm using for the fresh air intake to fit around the starter motor nose - i'll rivet some aluminium sheet to the duct to close off the hole i've made 

 

 

trial fit of the carburettor and filter showed that the filterking regulator location i'd chosen wasn't going to work, so looks like i'll be going back to the K&N cone filter setup.  Main reason for going for the ITG setup was because it supports a stubstack, but i'll have to see whether the stubstack can be modified to fit the K&N filter

 

 

Battery cable installed, engine steadies fitted, exhaust in place but need to get hold of the right centre and rear mount fittings before it's done

 

 

...next job on the list is terminating and wrapping the front lighting & engine ancillaries loom

[I hate Brian]

Coming along nicely, it got the ITG filter assembly for Med mine fits okay a little tight but doable

[KTS]

had the last week off work, and after a few days spent making good progress clearing my parents house, managed to crack on with the pup

exhaust now fully mounted: competition rear mount and 1.75" manifold clamps should keep it all in place

 

next job was finishing off the lighting and engine ancillaries loom - not a big fan of bullet connectors for the headlight/indicator connections, so used deutsch DT series pins and sockets as they are much more compact.

 

 

..just need the correct terminals for the alternator plug and that will be complete

 

 

next job was to try and figure out how to fit the Saab 95 heater valve that i'd modified a long while back

 

i had been thinking that putting the valve behind the take-off with a 90degree to connect it would work, but with the engine in the car it was obvious that wasn't going to work as the bonnet reinforcing ribs would have fouled, so after lots of head scratching (..it did get to the point where i was considering using a 3 way ball valve instead..) I came up with a solution.

 

first; make a bracket

 

 

fix the bracket to the head using the take-off bolts, so the valve could be mounted off the end of the head, and make a link pipe out of 15mm copper pipe to connect the outlet to the valve

 

 

then connect up the rest of the pipe work to give a system that ensures there is always coolant circulating out through the heater take-off: depending on the valve position it will return direct to the pump inlet or will run through the cabin heater

 

 

having ditched the ITG filter in favour of a K&N cone filter, the filter/regulator was put back and a link pipe for the carb fuel feed was made up. I also fitted a bracket to the bulkhead to locate the lambda sensor connector

 

 

 

a bit more cutting, filing and bending of 2mm stainless sheet resulted in these

 

 

..which were used to hold a piece of felt underlay in place across the hole in the bulkhead - that should help keep the noise levels down.

Edited by KTS, 18 April 2022 - 08:07 PM.

[KTS]

...and because i've re-routed the plumbing, with additional wiring under the dash there's no way i'd be able to run the heater hoses over the heater unit to the matrix inlet & outlet, i've had to swap the matrix around, so need to add repainting the heater unit to the 'to do'list

 

Edited by KTS, 18 April 2022 - 08:27 PM.

[KTS]

Blimey; where does the time go !!

 

Work on the pup has had to take back the seat recently, so not a huge amount of progress, but is getting there incrementally..

 

Just about used up the last of the touch up paint on the rocker cover

 

 

re-painted and re-assembled the heater unit

 

 

after baking the rocker cover to get the paint to harden, i made up a carboard former to hold the gasket in the right shape, and then stuck the gasket to the rocker cover with RTV sealant.

 

 

..that meant i could finally fit the rocker cover and fill the engine with oil !!

 

 

The following day, i was happy to find there wasn't a pool of oil under the car, but having close look underneath did reveal a drip of oil on the offside pot-joint   .  After much muttering and a soothing cuppa, i got back under the car to wipe the oil off and was relieved to find that it was not the oil i'd filled the engine with but green duckhams which i'd been using when re-assembling the engine.  Using a different oil for assembly was pure chance, but something i will continue to do from now on.

 

one bit of remedial work that does need to be done is rewelding the boss for the lambda sensor - as it sits at the moment the sensor tail is just about the lowest thing underneath the car which is just asking for trouble 

 

  

[KTS]

Another job i've managed to complete was fitting the auxiliary fan and completing the fan and sensor wiring..

 

A rummage through the miscellaneous aircraft fittings that i'd retrieved from my stepdads garage turned up some that i figured i could make work (..i have no clue what they are supposed to be !)

 

 

Anyway, with short sections of fuel pipe and engine steadies fitted to them, they make pretty good mounts to fit the fan to the innner wing

 

 

fan sensor and fan power wiring complete and working

 

Edited by KTS, 29 May 2022 - 07:39 PM.

[sonscar]

Nice work,llambda sensors should point downwards to help prevent condensation damaging the sensor tip,about ten degrees or so,Steve..

[IronmanG]

Lovely Pat

[alex-95]

Great work, coming along nicely now! I'm liking the cardboard rocker gasket former!

[ac427]

first step, clean it
 

 
..and clean it some more, 'til it looks like this
 


 
..then moisturise it endlessly 'til the leather softens up and a lot of the finer cracks disappear..(..tried lots of different products for this, but found E45 hand cream gave great results)
 

What product did you use to clean the leather?

[KTS]

What product did you use to clean the leather?

 

 

LeatherGenie cleaner;  I found it under the kitchen sink.  amazing what you find in there....

[KTS]

managed to get some hours in over the long weekend to get a few more bits done

 

first up was to cut back most of the weld around the lambda sensor boss so i could twist it into a better position.  just need to get it tig welded now

 

 

the other job was to sort out a misaligned tailgate latch.  nearside latch was fine, offside not

 

 

the retainer looks to be made from 1/8" steel, but i didn't have any of that, just some 4mm rolled steel bar left over from making the seat frames, which after some gentle persuasion with a club hammer created a passable replacement

 

 

after some careful measuring up, drilled the holes and painted it

 

 

..and it now works 

 

[KTS]

..another couple pieces of the jigsaw in place 

 

first off; where/how to mount the air-horns.  the typical (?) spot on the inner wing above the clutch housing can't be used as the fresh air ducting runs through there, so had to find another home.   there's space between the alternator and starter motor as i've got no distributor, but nothing really to mount them from, so....

 

..make another bracket..

 

 

..and mount them off the cylinder head studs. 

 

 

The other piece is the modification of the MED stub-stack that i bought to use with the ITG filter, but couldn't fit, so had to revert back to using the K&N cone filter

 

Started by measuring it up against the K&N filter back plate to work out how much needs to come off to fit within the radius of the K&N filter.

 

 

..then, the long and laborious job of reprofiling it to match the angle of the filter

 

 

..eventually, i ended up with this

 

 

..the original mounting bracket the top plate fixes to was in the way of the stub stack, so a replacement knocked up

 

 

..and fitted 

 

Edited by KTS, 25 June 2022 - 03:50 PM.

[longtimenomini]

Looking great … fantastic details

[DUF2]

Re Horn location. There is precious little space under the bonnet for air horns.

on my Elf I have located both the compressor and the trumpets under the offside wing. I also relocated the screenwash bottle into the boot by the fuel tank, mind you the extra length of the Elf boot made that easy!