Archive for 2013

Progress

Posted: 19th December 2013 by asteriskr in K16 PUG
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Over the last few months it’s been hard to find time to progress the Maxi, nonetheless it has moved forwards. In summary, both front wheel arches are now tubbed for the larger wheel size as per the works cars, the engine mount and gearbox mounts have been reworked to allow for a 1.6 litre TU-based engine (as opposed to 2.0 litre XU) and Sadev sequential box (which was made possible thanks to a loan of a dummy casing from SWR Motorsport) to be fiited. Bit of work needed to finish the job but it is nearly there.

engine bay

Bought one or two things such as this customised oil catch tank, which is a copy of the works tank.

Maxi works catch tank

Tidied up the front end a bit and the car has now gone into storage pending a house move.

Front end

Goodbye Workshop

Posted: 18th December 2013 by asteriskr in K16 PUG
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After 8.5 years effectively renting in the current place, I am moving on and the wife and I will be buying our first house together. I’ll be saying goodbye to a double garage which I shouldn’t complain about because it’s allowed me to do loads, but it’s given me a very good idea about what I want from a garage and workshop in future. Only having two power sockets is limiting, no insulation is bloody cold, metal roof structures cause condensation like nothing else and if you don’t want leaves, fag ends and other crap blowing under the door, then you need brush strips (which I did fit in the end and will be taking with me) and bare brick and concrete generate loads of dust. Fingers crossed everything pans out in the New Year – look out for a build thread on garagejournal.com.

Final prep work on the car confirmed that it’s never simple to get stuff done. The OMP seats and sidemounts won’t fit. The tunnel still has the winged section on it that the standard seats mount onto and consequently the seats are either up against the door bars or up against the tunnel. The mounts welded to the seat bars are not equally distanced from the centre, it’s a good thing that they are in the wrong fore/aft positions anyway otherwise I might be quite upset. The need to chop them out is confirmed and I will something like I did on the Rallye (as per the pic below) in future.

Rallye 16v Interior

With everything that needed to be loaded up, the car has gone into hibernation…

Adios

Getting Ready To Go

Posted: 16th December 2013 by asteriskr in K16 PUG
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In the box of bits that came with the car was this Sadev gearbox mount. Nice find as it allows me to try and get the mounting spot on.

Progress

Well kind of, all the reference points to work out where the original gearbox mount were are long gone. Measurements were needed and with thanks to some of the guys on 106RR I was soon able work out where the mount needed to be. Rummaging in the scrap metal bin revealed some 5mm metal plate which was hacked and drilled appropriately.

The threaded insert for the gearbox mounting bolt on the Sadev plate is angled so that the engine is tilted slightly forward. My thought is that this is so the box clears the wishbone mountings. When Diesel Dave fitted his, he had to chop a big chunk out, but none of the works cars seem to have needed this so I suspect that it’s all down to the positioning. The immediate issue I have is that the reinforced rear engine mount is in the way so this will need trimming to give clearance…

Progress

On the engine side the whole lot needs to move over to the gearbox side by about 8mm. The standard gear box mountings have a 15mm slotted hole to facilitate some adjustment so I reckon that I’ll get away with the move. Just need to be conscious of the drive shafts…

Well there was no way that the box was going in without the passenger side wishbone getting a cut out to give room. The necessary surgery was done tonight and the engine and box can now fit in the correct position – suitably low, square and tilted. Next job is to fabricate up the base that the C2R2 Max engine will sit on…

I’ve been really busy, but I am now officially on leave having finished my job on Friday. On Saturday afternoon my Dad turned up with his new Ifor Williams trailer and the pressure was really on. I managed to get a couple of hours in on Saturday morning and have just pulled a 12 hour stint today and finally have it ready to go on it’s holiday into storage… So here are the updates in pics.

Gear box mount was fucked so bought a new one of Baker BM. Bloody good customer service – it was here in less than 48hrs.

I’ve been really busy, but I am now officially on leave having finished my job on Friday. On Saturday afternoon my Dad turned up with his new Ifor Williams trailer and the pressure was really on. I managed to get a couple of hours in on Saturday morning and have just pulled a 12 hour stint today and finally have it ready to go on it’s holiday into storage… So here are the updates in pics.

Gear box mount was nadgered so I bought a new one of Baker BM. Bloody good customer service – it was here in less than 48hrs.

Progress

The makeshift and temporary gearbox mount was reworked and cleaned up. It’ll do for now, but I will need to get one properly made before the car is used.

Progress

I fabricated up this base for the engine mount, got bored of taking lots of photos, so just cracked on and fitted it with weld in 8mm threaded inserts. Finished the wheel tub (long story about getting it to match the other side) and made a few little tie in gussets. Looks okay I think.

Progress

Progress

Fitted a reinforcing piece to the wishbone mount. Again this will do for now. I will put in some extra reinforcement on the top at some point in future. This maxed out the 13amp supply I was running off. Had to reset the trip switch about 6 times. looking forward to getting a workshop with a proper supply in future…

Progress

Progress

Engine and Sadev box in for final check and all is good. Thank god.

Progress

Lots of cleaning up, tidying and then reassembly

Progress

Tomorrow it’s a case of Dad and I chucking all the other bits on the car (as much as possible), so it’ll be seats and harnesses in, etc. Then off it goes and I won’t be doing anything else on this until I have a new home in the North East.

Engine Mock Ups

Posted: 1st December 2013 by asteriskr in K16 PUG
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Managed to scavenge a couple of hours in the week. Primed the chassis rail leg and then put in the inner wheel arch top. It’s not worth doing the side until I have the engine mount positioned as it give access.

progress

progress

A small repair was needed to the chassis rail:

progress

progress

progress

I also decided to reinforce the chassis rail leg. Hockly has done the same on the gearbox side…

progress

This plate was adapted so that I could get the two chasssis rail tops level. Once it was welded on, I used the open access from the wheel arch side to weld a thin section to the top of the existing chassis rail top to make up the difference in height and give a good 3.5mm thickness to support the new top plate. This was supposed to be 2mm thick, but the stock supplier I used only had 3mm box, so I chopped what was needed out of the 100mm x 100mm section. This job has been on my mind all week and I have been sketching out cross sectional diagrams and such stuff to help work out how I was going to do this. Worked out as planned in the end. There are a few finishing gussets to tie into the chassis rail needed.

progress

Did a bit of shaping and finishing and tacked the top plate in square and level. Then it was time for the engine mount.

So gearbox and bell housing adapter plate bolted up to the block, hooked up to the crane and into the car.

progress

progress

Unfortunately the EW must have been setup to mount in such a way that the gearbox side mount makes the whole thing sit too high. So that will either need major rework or a whole new mount making up.

Found some very long 80mm bolts for the gear box and dropped the height down. It needs a bit more of a drop, but I had run out of motivation and time by this point. At least the bonnet now closes.

progress

On the engine side the C2R2 Max engine mount looks like it is not going to work out. I may modify the original EW mount and reuse that in part. The passenger side wishbone mount also nears a section chopping to accommodate the Sadev box so the job is substantially more complex than originally planned as with all of the above, the rear engine mount also needs major rework…

Sadev Part 1

Posted: 26th November 2013 by asteriskr in K16 PUG
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Made some headway over the last week. Lots of measuring and measuring again and then chopping. Where the hell did two and a half hours go this afternoon…

Tidying

Bit more progress than the photo above suggests but not much as there was a lot of thinking about engine positioning. Particularly how to work out how far from the bulkhead the back of the block should be which is complicated by the fact that the gearbox side is setup for the Sadev and I’ll be running the BE until I can upgrade. So there’s no reference point on that side either. I want any to get it right first time as redoing it will be a pain.

I spoke to SWR Motorsport who are the Sadev importers and they have a dummy casing for this exact purpose. As I’ll also need to buy a TU bell housing, SWR put me in touch with a customer who has one that has become available. This meant that by today I had some trick gearbox content to share:

Sadev

Sadev

Sadev

Alas only the dummy box on loan from SWR Motorsport, probably the closest I will be to one of these for at least the next 18 months. The TU bell housing is now mine however…

Sadev

Sadev

Sadev

Flap discs, slit discs and metal stock in the post, should be able to make some headway at the weekend…