cheers benn, would be nice to have it ready for the action day in sept but may be pushing it.Quote:
Originally Posted by Benn
I do like a nice clean bay
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cheers benn, would be nice to have it ready for the action day in sept but may be pushing it.Quote:
Originally Posted by Benn
I do like a nice clean bay
Not ready for pv then... lol
no. :(
really keen on spectating this year though, just hope the weathers good.
Shame, but cool.
update
nothing spectacular for an update, few more parts have arrived so more of the puzzle is coming together.
finished painting the fuel rail in black
http://i193.photobucket.com/albums/z...ps15ae3337.jpg
removed a few lugs off the turbo compressor housing and then painted in VHT paint.
http://i193.photobucket.com/albums/z...psd5d77967.jpg
as I already had a forge actuator for my old k16 (which I changed to a higher rated spring just after I stopped using it), I wanted to keep it and hopefully mod it to fit the evo turbo. I contacted forge about this and they sent me a host of parts.
http://i193.photobucket.com/albums/z...psb523c75a.jpg
some wernt needed and a slight modification to the rod meant it fitted quite nicely.
http://i193.photobucket.com/albums/z...ps23002b49.jpg
got the valves out of the head ready for my new valve springs to turn up, was expecting them to arrive this week but they havnt. gave the inlet port a slight taper to match the gasket/inlet manifold aswell.
http://i193.photobucket.com/albums/z...psec6f4b0e.jpg
a set of china special conrods came in the post aswell, I have been quite dubious about getting a set of these but after very close inspection by me and a few colleagues they seem pretty good quality. even comparing them to a set of cat cams and arrow rods, they look nigh on identical in finish. whether they can with stand the same sort of forces will be told in time
http://i193.photobucket.com/albums/z...psa7cf737b.jpg
also to come in the post was a set of ARP head studs and a wide band lambda bung. more parts should be coming next week.
I need to get on with the bay ready for paint but ill be waiting until I can move it up to a mates workshop after PVS
thanks for looking.
Nice work brucer
Really like clean parts
me too :)
update
Since the last update ive been pottering on with various bits and bobs, the gearbox being an item of many. I wire wheeled all the old paint off and gave it a a new coat of silver, along with cleaning up the carbon fibre plate which makes it very sexy.
http://i193.photobucket.com/albums/z...ps26c55e5a.jpg
http://i193.photobucket.com/albums/z...ps501ea476.jpg
One thing I did notice was that the gearbox mount had broken off the top bolt hole on the box, now it would have made more sence to have it repaired if I had the bit that had come away or more time and money. With set on making something work for now I decided to make a new plate that would tie in with the other 2 bolt holes and then attach to the back of the block.
The plate was made and should hopefully work, trial fitment will have to wait until the engine and box go back together. I do have a steel tube to go between the plate and the block.
http://i193.photobucket.com/albums/z...ps30ea24b8.jpg
Whilst on the gearbox area, I retried my rose jointed gear linkage I made years ago. Im still not happy with how tight it is and with it being impossible to set it up correctly when I tried ages ago I gave up on the idea. The linkage I was using was a standard item but it had play in the bushing, with always trying to save money I devised the plan to cut it open and fit some rubber pieces I had about into it. This was done and then tacked back up, it took all the slack out and will be ok for now.
http://i193.photobucket.com/albums/z...psce2777e5.jpg
Onto the car, I took it into work so I could weld up some of the holes I didn’t want any more. Also tidied up various other engine bay discrepencies.
http://i193.photobucket.com/albums/z...pse10f523f.jpg
http://i193.photobucket.com/albums/z...ps378eedb2.jpg
http://i193.photobucket.com/albums/z...psb5d5465f.jpg
Some people may know I usually run the engine loom through the o/s cap that bolts onto the bulkhead. Space is very limited in the cock pit due to the pedal assembly. Using a small belt/finger sander I managed to take some of the material away leaving me much more room to play with. The Z20LET loom isn’t as big as C-LET so this should be ideal.
http://i193.photobucket.com/albums/z...psc7fe9304.jpg
http://i193.photobucket.com/albums/z...ps958ef42b.jpg
Another way I was trying to save money was to make my own top hat for the Z-LET throttle body, the flanges can be bought off eBay along with a 90degree stainless pipe.
http://i193.photobucket.com/albums/z...ps9d280c2a.jpg
I had to bore the flange out to get the angle I wanted with the pipe, was somewhat limited due to how the flange sits on the throttle body with the sealing ring. This will get welded up by Adam dewis along with my intercooler and my sump.
http://i193.photobucket.com/albums/z...ps275a13e3.jpg
As my one rubber engine mount had torn slightly I didn’t want to re-use it, a quick call to euro car parts and I got a new one for £12. The previous ones had been filled with silicone but read somewhere that they fitted bits of rubber in-between to increase rigidity, tyre valves were the item of choice and done a good job in filling the small holes once cut up.
http://i193.photobucket.com/albums/z...ps9adeb0aa.jpg
David Dixon come up trumps with an equal length shaft which I then painted black, also Alex j sold me the dummy part to make a complete set up, this too painted in black and silver.
http://i193.photobucket.com/albums/z...ps6ec7e491.jpg
Tidying up the engine bay even more was to get some pipes added to my intercooler, I really didn’t plan on cutting the intercooler as it’s a forge item and for some reason I just didn’t want to do it, but I had no choice to as it gave the angles I needed.
http://i193.photobucket.com/albums/z...ps5ccd69dd.jpg
I took the block into work and stripped it down ready for the new rods, these got fitted quite simply.
http://i193.photobucket.com/albums/z...ps8ffe8780.jpg
I gave the bore a quick deglaze and got the pistons back in, I then found out the ARP rod bolts that came out of standard rods didn’t fit in the new rods. Doh! I got the pistons fitted and cable tied the big end caps together temporarily.
http://i193.photobucket.com/albums/z...pseadfbee9.jpg
Ill be sending the sump off to Adam dewis to be baffled along with the other bits that need welding, so this was only fitted with a couple of bolts.
ARP studs fitted along with a new Z20LET elring gasket.
http://i193.photobucket.com/albums/z...ps2445e352.jpg
Head torqued down, cam pulleys fitted and timed up, I had to return the inlet pulley back to standard timing marks as im now using both XE cams.
http://i193.photobucket.com/albums/z...ps4bfa9ff2.jpg
As im using the z20let coil pack I had to modify the cam cover slightly for it to fit, I was hoping it would be mounted low enough so the plug cover would still go on. I wanted to remove minimal material from the cam cover for the coil pack to fit, in doing this I had to modify the plug cover.
http://i193.photobucket.com/albums/z...ps8bb9e9c5.jpg
http://i193.photobucket.com/albums/z...pscdc7e287.jpg
http://i193.photobucket.com/albums/z...ps4defeb47.jpg
http://i193.photobucket.com/albums/z...ps3f6ce5fc.jpg
http://i193.photobucket.com/albums/z...ps3ea3fad2.jpg
It sits up higher on the one side which I cant help as the coil packs plug is the highest point, I may use Velcro to stick it down which will level it out even though it will be higher than the cam cover. Will have to wait and see on that front.
Also fitted was the alternator with drilled out mounting bracket holes, this has given me more scope for aligning the belt as before it was on an angle and kept coming off. I lost one belt on the strip at shakey. lol
http://i193.photobucket.com/albums/z...ps2e1081df.jpg
Next week will see the engine bay painted and hopefully the engine fitted back into the bay. Yippee!
Thanks for looking.
Bruce
Tasty looking engine Brucer, what power are you aiming for this then?
So it will be a Clet running Zlet management? Kinda cool, what the reason behind it?
Bay looks good. You've done just what i'm gonna where the loom enters the cabin.
Zlet management is mappable iirc. So no need for aftermarket management and safer when running big powers. ;)Quote:
Originally Posted by Benn
Interesting read them last few pages Bruce, I'll have to try catch you at a show some time.
thanks southie, aiming for 350+, nothing too ridiculous. lolQuote:
Originally Posted by Southie
as nick said, its mappable. granted it doesn't have as much scope like omex,dta etc but for what I want its more than ideal.Quote:
Originally Posted by Benn
its also different to what everybody else has done, as far as im aware the only other c-let in a nova with it fitted is boost beast. it does have a different spec to mine but their making 470hp per motor with the z-let loom.
Quote:
Originally Posted by scott.parker
defo scott, unsure what will be the next one ill be attending, most likely next year now.
Update
Back again with an update, something I forgot to upload last time was the fly by wire throttle pedal which I got mounted to the bulkhead.
I didn’t want to butcher the bulkhead too much incase I wanted to revert back to a standard pedal, as I wouldn’t be using the cable for the throttle pedal this hole was more than adequate to use. Another hole was available next to this and a lower one had to be drilled. I made a small plate with 2 studs welded on to spread the load on the upper holes as I didn’t want the thin bulkhead tearing.
The pedal angle had to be modified to fit in line with the novas pedals, along with making sure the pedal bottomed out nearest the floor so no stress was put on the pedal internals or bulkhead.
http://i193.photobucket.com/albums/z...ps7f03df6f.jpg
http://i193.photobucket.com/albums/z...ps0c79dc36.jpg
The car got taken down to the paint shop to have the engine bay painted. 2 days later I got the car back ready to build back up.
http://i193.photobucket.com/albums/z...ps8b6df279.jpg
http://i193.photobucket.com/albums/z...psa63025b9.jpg
As I had the week off I was able to crack on, getting a lot of jobs done with what parts I had.
First off was to install the spare rack I had painted previous, old one off, rack boots swapped over and then fitted along with the servo.
http://i193.photobucket.com/albums/z...psca175fc5.jpg
http://i193.photobucket.com/albums/z...psb93c9162.jpg
Getting on to the big part of the week, installing the engine without scratching the new paint! The billet flywheel and sachs clutch got fitted with the box being bolted up next.
http://i193.photobucket.com/albums/z...psfe5a3b2c.jpg
Going back to my last updates I had modified the rear gearbox mount, I trial fitted this to make sure it would fit to the block with no issues.
http://i193.photobucket.com/albums/z...psc2658665.jpg
All ok with this meant the engine could be dropped in from the top.
http://i193.photobucket.com/albums/z...ps077eff64.jpg
http://i193.photobucket.com/albums/z...psf62723fc.jpg
I bought these plastic bolt covers to try out, I did want all my bolts zinc plated but this would have cost a lot more and I always new id forget some that would need doing. wasn’t sure if they would look tacky but Im quite happy. There not going to be on show that much so wont be noticed by all, just tidys up niggly bits.
http://i193.photobucket.com/albums/z...psd2fe40f5.jpg
Half shaft fitted, as you can see the modified rear mount too.
http://i193.photobucket.com/albums/z...ps74a23aea.jpg
Shafts also fitted, gear linkage setup and starter/alternator wired in.
http://i193.photobucket.com/albums/z...ps1fe33ebe.jpg
http://i193.photobucket.com/albums/z...pse7807930.jpg
As you can see the top hat sits too high and looks stupid, more mods to this will follow.
z-let loom trial fitted to figure out the best routing.
Compared to a c-let loom, this is a thousand times easier to position/hide and lengthen.
http://i193.photobucket.com/albums/z...psc0465143.jpg
http://i193.photobucket.com/albums/z...pseed96ceb.jpg
These pictures show how hidden the loom is, the injectors across the top will now be run under the inlet. The AFM wiring needs to be over the gearbox, coil pack wires had to be lengthened, front BCS is under the inlet, the long section of wiring going over the top of the gearbox now goes under the inlet through into the cabin, the CTS needs lengthening to go under the engine upto the original position. MAP sensor will be rerouted once I know where im mounting it etc.
http://i193.photobucket.com/albums/z...ps1a367f36.jpg
http://i193.photobucket.com/albums/z...ps4c5255c3.jpg
http://i193.photobucket.com/albums/z...ps3dd2179c.jpg
I finally got round to having ago at the fuel system when I ran out of things to do with the engine. I bought myself a rivnut tool so I could mount the swirl pot in the boot.
http://i193.photobucket.com/albums/z...ps171bb06d.jpg
Fuel returns fitted along with the feed to the main bosch 044. Clips for the lines have arrived today and will get fitted at some point.
http://i193.photobucket.com/albums/z...pse72c6901.jpg
As I already have copper lines running through the car it made it easier to fit the swirl pot and new lines. The return from the rail now goes back to the swirl pot, where as the return from the swirl pot now goes to the return on the tank.
http://i193.photobucket.com/albums/z...psa950d620.jpg
I just need fit the lift pump and line for this to the swirl pot, also the main pump in the original carrier which is too small.
Ill be collecting a load of bits again ready to have another big attack at it.
Thanks for looking
Bruce
http://i193.photobucket.com/albums/z...ps639edd8d.jpg
Nice work Bruce
One thing red calipers and red alloys
Not sure mmmmmmmrrrrrrrrrrrr
But overall I like a lot
Looks great! Much tidier ;)
Good progress Brucer, Need to see some aeroquip fittings though ;)
Cheers, the calipers suited my softstars but these got stolen. The cesaros have now become the more permanent wheels atmQuote:
Originally Posted by 7ova
Thank you. :thumb:Quote:
Originally Posted by M Sutton
Thanks, i know but the price per fitting i cant justify atm. Im unsure how well the teflon hose will create a seal so i may have to revise it all again to proper fittings. Theres no real pressure any where in these lines.Quote:
Originally Posted by Kev Turbo
update
Not really an update as such, just a list of various parts that ive collected again ready to get stuck in with the car once again.
bosch 044 fuel pump with barbed fittings, the casing has seen better days, god knows what the previous owner had done to it. lol
http://i193.photobucket.com/albums/z...ps60711795.jpg
Finished altering/making the tophat as pictured from a couple pages ago
http://i193.photobucket.com/albums/z...ps217d40f6.jpg
various silicone hose and step down adapters for the turbo coolant lines
http://i193.photobucket.com/albums/z...ps270c7e04.jpg
vacuum hose
http://i193.photobucket.com/albums/z...psddbb98fc.jpg
ARP rod bolts for the steel rods, thanks to Philip. (as the arp ones from my standard rods didn't fit)
http://i193.photobucket.com/albums/z...ps95dfe4ab.jpg
siemens deka 630cc injectors
http://i193.photobucket.com/albums/z...pse6578f1a.jpg
fuel hose clamps to tidy the interior and allen bolts for the dizzy blank
http://i193.photobucket.com/albums/z...ps5f357c50.jpg
corsa C header tank and a aluminium tube for a dump valve tank off on the intercooler.
http://i193.photobucket.com/albums/z...ps851fc22f.jpg
wideband lambda bung for when I have a down pipe made.
http://i193.photobucket.com/albums/z...psff3203c3.jpg
some cheap heat wrap and ties with a new can of heat proof paint.
http://i193.photobucket.com/albums/z...ps0d6e3da5.jpg
a stainless evo manifold with a c20let head flange courtesy of david Dixon.
http://i193.photobucket.com/albums/z...ps9d869e7b.jpg
bigger update to come soon.
bruce
Watch the top inlet on the header tank, they are mega weak.
Liking the parts collection.
update
To get the car useable for next year the only feesable way was to get a cheap manifold to use for now until I can get james middleton to sort me out one of the ones he gets made.
The manifold needed to be reflanged to suit the engine as it was originally off an Evo 6, cutting off the top bolt holes and redrilling the bottom holes to line up with the c20let flange. As this was ment to be a budget manifold I opted to weld the flange on myself using a standard mig welder. Using thick 'c' shaped beads meant it gave a good spread of weld to seal the two together. I also welded in a brace between the flange to the turbo flange to try help carry the weight of the turbo and stop the manifold cracking.
http://i193.photobucket.com/albums/z...ps6570d8c2.jpg
http://i193.photobucket.com/albums/z...ps301132ba.jpg
http://i193.photobucket.com/albums/z...ps6ec95574.jpg
http://i193.photobucket.com/albums/z...ps1c14bbef.jpg
happy with the results I used some hammerite heat paint to cover the welds and make the manifold look nicer. Also, to try keep the heat down in the bay I bought some cheap heat wrap to cover it. The pics of the centre runners only have 1 covering, but I have now put a second layer around due to it going to be close to the radiator(if it fits).
http://i193.photobucket.com/albums/z...psf9e76165.jpg
http://i193.photobucket.com/albums/z...psdfa8792e.jpg
http://i193.photobucket.com/albums/z...ps062bc57a.jpg
http://i193.photobucket.com/albums/z...psdc38f15f.jpg
http://i193.photobucket.com/albums/z...ps222a557a.jpg
The first trial fit in the engine bay was productive, the manifold fits on nicely, although quite large and will require the slam panel to be modified. I new this was going to be an issue but shouldn't pose too much of a problem. Offered the turbo up and got one bolt on, the lump on the back of the compressor housing fouls the dipstick(also new this would happen but was unsure on the extent) and the actuator wont fit in its original position due to how low it is with the front cross member.
http://i193.photobucket.com/albums/z...ps3ab86d51.jpg
http://i193.photobucket.com/albums/z...ps0b61cde8.jpg
http://i193.photobucket.com/albums/z...ps5362d48e.jpg
http://i193.photobucket.com/albums/z...ps4cbffe88.jpg
Cutting down and grinding the lump from the back of the turbo as much as I dared gave me a few more mm of clearance, the dipstick tube will get heated up and bent back for more. Hopefully will give me enough room but we will see. Another hole for the actuator bracket was drilled and spaced out using washers to give the desired effect, the actuator arm has to be altered which I will assess next week.
http://i193.photobucket.com/albums/z...psb0928467.jpg
http://i193.photobucket.com/albums/z...psee2b1dc1.jpg
http://i193.photobucket.com/albums/z...psd8ef7f49.jpg
All in all, its been a productive week with some easy fixes to solve the problems ive come across so far.
Thanks for looking
bruce
Some good quick progress, it's looking good mate.
Love this car and love it more cause you just want to go faster
Thanks alot, loseing some weight out of the car would make a big differance but i want to keep it looking decent.
Got a couple more bits done today that ill up date at some point.
Thanks alot, loseing some weight out of the car would make a big differance but i want to keep it looking decent.
Got a couple more bits done today that ill up date at some point.
Turbo set up looks great.
update
had a day off last week so was able to get more progress done with the nova, excuse the bad pictures.
a few items were plain sailing but some have thrown up a few issues that need to be revised.
first off the easy parts, top hat fitted and checked for clearance.
http://i193.photobucket.com/albums/z...psdc94a414.jpg
http://i193.photobucket.com/albums/z...psa9dfe89d.jpg
fuel rail fitted with the siemens 630cc injectors then fitted to the inlet with the wiring connected. I do plan on getting some new conduit to cover up the loom, even though the loom isn't that old compared to a c-let item. Need to clean the connectors too.
http://i193.photobucket.com/albums/z...psef858864.jpg
fuel pressure regulator repositioned slightly compared to how it was before, using a cap head bolt into a hole tapped out.
http://i193.photobucket.com/albums/z...psea0576e5.jpg
Fitted a few of the zinc plated parts I got back.
http://i193.photobucket.com/albums/z...ps12f09456.jpg
http://i193.photobucket.com/albums/z...ps537028e6.jpg
Cap head bolts replace the standard bolts I had fitted in the dizzy blank
http://i193.photobucket.com/albums/z...pse73d6d14.jpg
Arp rod bolts torqued up and sump, the sump had a lick of paint whilst removed.
http://i193.photobucket.com/albums/z...ps0a40b0d0.jpg
http://i193.photobucket.com/albums/z...psa2d0a447.jpg
A new temp sensor plug was sourced to replace the original which had the wire pulled out of the connecter, the wires also got lengthened to accommodate the route its taking under and across the sump.
http://i193.photobucket.com/albums/z...ps7a577882.jpg
Trying out the turbo set up once again for clearance, the actuator now clears the lower panel. I think im going to alter the angle of it again so the actuator sits more inline with the travel of the waste gate arm.
http://i193.photobucket.com/albums/z...psa43eca42.jpg
trying the radiator in place gave me the realisation of why off the shelf manifolds don't work in places they arnt designed for.
http://i193.photobucket.com/albums/z...psc1fe4dea.jpg
http://i193.photobucket.com/albums/z...pse775aea2.jpg
With the intercooler in the usual position, the space is very limited for a radiator. Only options are to move the intercooler forward/change the manifold/get the head flange machined down 4-5mm and alter the waste gate arm pin.
http://i193.photobucket.com/albums/z...ps40c5f0ff.jpg
I don't want the intercooler moved forward as it means modding the bumper, changing the manifold to a custom job is going to be £650, so I think ill try the 3rd option and see how much room that creates.
Heres some more pics with the rad fitted and tipped out at the top, this is only possible with the rad over slightly to miss the end tanks of the intercooler. More mods to that will follow too. The rad fans will have to go on the back side for this also.
http://i193.photobucket.com/albums/z...psad361a14.jpg
http://i193.photobucket.com/albums/z...ps513bf7ed.jpg
http://i193.photobucket.com/albums/z...psd74a42d5.jpg
Thanks for looking.
bruce
Bruce why not use a civic eg alloy radiator? They stand to one side and work fine with huge power hondas.
The tilted rad could work on as long as you can get the grille in. What about shaving afew mm off the exhaust flange?
Civic rads too tall in a nova, tried that. Brucer im gonna make up 5 or so c20let/evo turbo manifolds in the new year, would you be interested?
looking on ebay there about 10-13cm taller than a nova one, I did search for some others but nothings shouting out at me.Quote:
Originally Posted by nova_stee
that is one of my options benn, have been messing with the turbo today to alter the wastegate arm. I need to cut the slam panel about before I can try the grille, didn't want to do that until I had a final position for the turbo/manifold.Quote:
Originally Posted by Benn
ummm.....maybe, depends on style and cost. got any rough design ideas?Quote:
Originally Posted by _Jake
Im aware it needs to faily compact to fit in a nova, you cant really change the runner placement a great deal as its a twin scroll setup. ill post a pic up when i start on them.Quote:
Originally Posted by brucer