Archive for 2013

The Other Side

Posted: 22nd November 2013 by asteriskr in K16 PUG
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In the last 3 weeks I’ve been busier than a one-legged man in an arse-kicking contest, but in the last two nights have managed some progress, so here’s a quick update.

Passenger side wheel arch side was primed up after I’d finished the bulk of work. It needs a little tidying up still, but it’ll do for the time being. There’s still underseal in the arch so it needs doing properly at some point in future…
progress

progress

After a lot of thought and reconsidering option I decided that I’m definitely not going to run it with the 2 litre engine, so the mounts were redundant.

progress

progress

There is some repair work needed.
progress

Going…
progress

…Gone!
progress

Need to work out engine positioning next and spec out a mounting for the top of the chassis rail.

Chop Chop

Posted: 3rd November 2013 by asteriskr in K16 PUG
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Time to start chopping and welding… The original oil catch tank bracket had to go even to test fit the new one.

Fettling

Gone. Headlight fitted to check clearances.

Fettling

First attempt didn’t have the curves I wanted so started again. Sometimes cardboard just doesn’t cut it and you have to make some mistakes in metal.

Fettling

Better…

Fettling

Inner section made up from cardboard templates and tacked in.

Fettling

Half way through welding it in.

Fettling

Finishing.

Fettling

I tacked the two halves together from the inside, then ground back and welded from the engine bay side. Loads of penetration so that joint didn’t need anything else. Where it’s welded onto the strut tower the thickness of metal is getting on for over 3mm thick in the top half, so I welded it from both sides to be sure.

Trick Bits

Posted: 30th October 2013 by asteriskr in K16 PUG
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So a while ago I bought these from Earls and then sent them of to MC Racing composites in France.

Parts

Last week I received an email to say my production slot had just been reached and tonight when I came back from Durham these were waiting for me. Custom made carbon catch tank for the Maxi. Now I have this I am happy to crack on with the inner arches as I wanted to make sure this was going to fit to the curves of the inner arches that I am going to need to make. I did give a smile when I saw Mike Nash’s latest purchase.

Parts

Parts

Parts

The other significant part was this radiator cowling, to ensure all the air coming through the bumper is used for cooling the rad. I wanted this before fabricating the radiator mounts. So no excuses for not making some progress now…

Parts

Parts

Power Steering ECU Mount

Posted: 26th September 2013 by asteriskr in K16 PUG
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This is my busiest time of the year at work and I am flat out. That coupled with the parentals visiting for an extended weekend trip up North has meant very little progress. I had some 3mm carbon sheet left over from the steering wheel so using a cardboard template made this mounting plate.

Power Steering ECU

Then added a few mounting tabs to the cage and except for a little fine tuning it’s fitted. I now fully appreciate Stu’s comments about it being a dog to do any work in the car with a fully welded in cage with cross braced door bars. Almost lost a tip off a finger…

Power Steering ECU

Sent some shiny bits over to France. Some exciting stuff hopefully in production now. Waiting for Charles Hurst in NI to send some Citroen Sport bits. They’re hopeless in my experience and I’ll be on the phone to them tomorrow to chase them up.

Progressing

Posted: 12th September 2013 by asteriskr in K16 PUG
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Earlier in the week I had to pick up a 36mm socket for the hub nuts as the Sadev shafts are still connected up. That night in the garage I cracked out the breaker bar and the 6ft extension for it and went to take them off… and spun the tyres. There’s just not enough weight in the car to get traction. May have to try again once I get the engine and box in.

Managed a good stint on my day off today, even did my first bit of welding on the car. Primarily I am still cleaning and stripping the car. I am going though a lot of degreaser. The Accusump pipework was leaking into the interior as two of the fittings were loose. Both driver and passenger footwells were full of engine oil combined with dirt and grit.

At Gatebil the car had an off into the gravel which had enough force to damage the engine oil cooler, snapping off one of the -AN fittings. A combination of this and catastrophic engine failure put engine oil over most of the bay, on the other side one of the gearbox cooler fittings was loose so there’s gearbox oil fairly well sprayed as well. Then there’s UJ grease on both sides because the gaiters on the shafts were gaffer taped up, but this didn’t stand up to track use. The car really was put together in a rush for Gatebil as evidenced by the lighting loom:

K16 PUG

I am not bothered by any of this – I knew what I was getting and the state it was in so it’s just a long road to being properly put back together now.

Here is the breather for the gearbox (i think) and some of the mess before cleaning.

K16 PUG

Sequential Oil Cooler and Pump. Now off and needs cleaning up before going into storage.

K16 PUG

Engine Oil cooler is not only missing a -AN fitting but is also bent…

K16 PUG

K16 PUG

Header tank won’t be needed anymore so it’s out. The rad and header tank will be for sale.

K16 PUG

And the outlet hole in the scuttle patched up. Fully welded, ground down, filled and primered now.

K16 PUG

In the interior, before I sold the Rallye I made up a template for the standard position of the Satchshift. Sods luck of course it won’t work with the controls in the car. I may shorten both the upper and lower bars rather than move the other stuff and put the leaver exactly where the sequential stick was mounted. Not 100% decided yet. I still want a Sadev in future, but can’t stretch to one for the foreseeable future so anything I do I want to be reversible.

K16 PUG

To fit the carbon foot trays, I had to modify the seat mounts. I’ll need the seats as far back as they’ll go, so I won’t need the front halves of the seat mounts on the rail nearest the controls. So chopped them off and the trays will fit. I’ll need to fabricate some little supports to clear the bracing on the front wishbone before I can securely mount them.

K16 PUG

The EPAS ECU was gaffer tapped to the back of the dash. I’ll make a mount and hide it away within the cage on some rubber mounts, like so.

K16 PUG