Ok, let me know.
Have got my manifold down at the engineers now, hes going to machine both flanges down, now that i cut the new flange back off
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Ok, let me know.
Have got my manifold down at the engineers now, hes going to machine both flanges down, now that i cut the new flange back off
Get a rad made? THey can't be that much....
Looking good bruce, where did you get your parts plated?
Looking to have some of mine done but in the yellow zinc
never looked into it, may be something I may do. still awaiting for the manifold back so I cant try it for fitment.Quote:
Originally Posted by Benn
There's a place in Hereford called Hereford metal finishers. There down by CMC tuning if you've ever been there, their small industrial estate is opposite taylor lane timber frame on the rotherwas bypass.Quote:
Originally Posted by Nutty Nova
I had this little lot done for a tenner. one or two parts havnt come out the best but I think its was because thy were quite rusted and pitted.
http://i193.photobucket.com/albums/z...psd7e45c4f.jpg
There's loads of places on the net that do them. Theyll make from what you have or even from cardboard... Which is good.
Didnt know you was doing this bud was that setup on ebay/facebook? Sure i got offered it. Im running the TD04 and looks like you will be running the air filter the same side as me should be fun getting it all in lol
I know the ones you mean but no there not. Ive been getting bits here and there for it.
I know what you mean, would be nice to keep it straight out the turbo to hide it behind the rad, but there wont be no room. I think above the gearbox like jonlem corsa is the next option.
IMO this needs the proper inlet manifold too.
Too right! But let me get it running with this one first! lolQuote:
Originally Posted by BRoadGhost
update
After getting my manifold and flange back from the engineer, I set about welding them together again. The manifold flange was taken down to 7mm and the head flange to 5mm. Gaining around 9mm in total
Both clamped together and welded together, all the ports had to be opened out to match head flange to give a smoother flow.
http://i193.photobucket.com/albums/z...pszol6dg0d.jpg
http://i193.photobucket.com/albums/z...ps9vx82czp.jpg
http://i193.photobucket.com/albums/z...psfrmcqopb.jpg
http://i193.photobucket.com/albums/z...psihslfg4d.jpg
http://i193.photobucket.com/albums/z...psxn6gdfv1.jpg
I offered the manifold up onto the engine again and although it gave me more room I wasn't happy with it. The compressor housing was now closer to the dipstick tube mount which would require alteration now. This along with having to cut more of the slam panel off than id like has now resulted in me binning this idea. Manifold is for sale if any body is interested. I have thought about changing turbo set up to something with a t3 mount.
Speaking to james middleton (jonlem) about the evo manifold his company makes had led to me to stick with the evo turbo. He was kind enough to send me out a template jig of the aforementioned manifold to check for space.
Measuring the difference in depth shows roughly half an inch of improvement, along with it being in an inch or two over to the offside.
http://i193.photobucket.com/albums/z...psqcy8grtd.jpg
http://i193.photobucket.com/albums/z...psofvoppse.jpg
http://i193.photobucket.com/albums/z...pslxdkhpjo.jpg
All bolted together with the radiator and intercooler fitted. The half inch difference in depth of the manifold has created the same amount of space between the rad and turbo wastegate arm. Im hoping the engine wont rock too much damaging the rad, I now have a solid rear mount fitted which should help. There is also 40mm of room behind the turbo compressor cover and block, which is ideal for when I go to a bigger turbo. Which im thinking of a td06sl2 20g or 25g.
http://i193.photobucket.com/albums/z...psmee27v0i.jpg
http://i193.photobucket.com/albums/z...pswnpzvyx4.jpg
http://i193.photobucket.com/albums/z...pss73mtqbr.jpg
http://i193.photobucket.com/albums/z...psldb9fed7.jpg
http://i193.photobucket.com/albums/z...pserfuy5hm.jpg
http://i193.photobucket.com/albums/z...psdklmyyri.jpg
P.T.O
continued....
http://i193.photobucket.com/albums/z...pseeiw5bq7.jpg
http://i193.photobucket.com/albums/z...pskayfogqp.jpg
bought some silicone hoses for making up a new boost pipe from the turbo to intercooler, have also bought some 19mm hoses and aluminium pipe to fabricate the coolant hose that will run inside the cockpit up to the bottom of the corsa c expansion bottle.
http://i193.photobucket.com/albums/z...psk5kjedps.jpg
http://i193.photobucket.com/albums/z...ps1bh17cej.jpg
http://i193.photobucket.com/albums/z...psg34gjaga.jpg
http://i193.photobucket.com/albums/z...ps6viyypow.jpg
Please excuse some of the bad pictures
thanks for looking
bruce
Brilliant progress Bruce and an enjoyable read, fingers crossed the new manifold solves all the issues you've come up against. I love the colour of it too, has made me think twice about painting mine Arden blue, I think the darker blues suit them a lot better.
Looking good dude.
thanks josh, I have been tempted to paint mine arden blue. lolQuote:
Originally Posted by josh-sri
cheers benn.Quote:
Originally Posted by Benn
update
Soooo....ive managed to take the car off the trailer to start on the nitty gritty and try to make it to pvs '15.
http://i193.photobucket.com/albums/z...psukntoyka.jpg
http://i193.photobucket.com/albums/z...psakpahs15.jpg
one little job was to modify my intercooler brace to gain some more clearance if I can possilbly keep my rad fans on the front of the rad.
I cut the centre part off and re-welded it at the front which has gained an inch of room, also managed to try out the and blaster I made at work. Its now got a coat of black on it instead of the grey.
http://i193.photobucket.com/albums/z...pswqh4uaif.jpg
http://i193.photobucket.com/albums/z...psadkrqcym.jpg
Also, bought some new parts. A 0.5L oil catch tank, a new swirl pot with AN fittings and various fittings for the fuel lines. Why I bought these will become apparent in a mo.
http://i193.photobucket.com/albums/z...pszeltxtal.jpg
http://i193.photobucket.com/albums/z...psgwfbdtnn.jpg
The swirl pot I had fitted was to be used with push on fuel hose, this would be fine If I didn't have Teflon fuel hose. I did try to clamp it with the hose clips, but it wouldn't go tight enough.
http://i193.photobucket.com/albums/z...psjbgawoaf.jpg
Debating whether to change to rubber hose would just fall short of buying all the correct fittings for the Teflon hose and selling the swirl pot almost paid for the new one. not a bad result.
All hose end fittings attached to the hose after I managed to master the technique.
http://i193.photobucket.com/albums/z...ps55pyy5e6.jpg
Hoses fitted and routed, need to figure out away to secure the twin hose holders down to the floorpan. Plans are to drill them out to accept an m4 bolt and then use a rivnut mounted in the floor to screw it to.
http://i193.photobucket.com/albums/z...psr9s1blmo.jpg
http://i193.photobucket.com/albums/z...pswt4fbl1h.jpg
fuel pumps fitted and wired in, used a new 30amp relay with some 30amp wire.
http://i193.photobucket.com/albums/z...psck0zdh36.jpg
http://i193.photobucket.com/albums/z...psugjnbmod.jpg
This pic doesn’t show the lift pump as I had issues with a broken union when I tried to swap it for the correct one.
http://i193.photobucket.com/albums/z...psvisaxmbp.jpg
next item on the agenda was the cooling system, a few pages ago I said I was going to use a corsa C expansion bottle up the scuttle. Before I had the bay painted I drilled the relevant holes to route the piping, now was the time to see if the holes were in a rough place to make a pipe.
Starting off with the 45degree hose cut down and fitted with a short piece of aluminium pipe to feed into the cabin.
http://i193.photobucket.com/albums/z...pspsimvcw0.jpg
Inside the cabin a 90degree hose was cut down and fitted to the previous pipe along with another alu pipe poking out into the engine bay. All that's left is to connect a hose from the rear of the water bar upto the bulkhead.
http://i193.photobucket.com/albums/z...pszin0okk4.jpg
http://i193.photobucket.com/albums/z...psbhi6rgj9.jpg
The catch tank has been fitted to the o/s inner wing with a rivnut fitting on the front panel. Access to the bumper bolts will be fiddly but manageable. Just need to order up some hose and fit/route it.
http://i193.photobucket.com/albums/z...pswtihrevd.jpg
another update to come over the next few weeks
bruce
A jubilee clipped coolant hose above your passengers feet?
Fortunately im billy no mates.:thumb:lolQuote:
Originally Posted by 8valve-craig
That's just where pipe work for my header tank used to be... worked great. only leaked once when at Combe.
Was that giving it grief or general driving?Quote:
Originally Posted by Benn
Only solution would be to use a 90deg steel bend, but i couldnt find one available in the correct size
Abuse on track, on the cool down lap my mates feet started to get wet... hahahaha I gave the tube a wipe f sealant and it never did it again.
Then moved it for more hidden look.
That was a bit of luck, would have been embaressing to be towed in.
I dont think ive seen your current set up
I've been towed in too :(
I move the tank over to where the battery would of been, pipe comes thought behind the inlet now.
Update
So PVS has passed and the car never made it, a lot of progress has been made though and it shouldn’t be long until I can try fire it up.
Here’s an update of what’s been going on since the last update…
The oil catch tank got plumbed in coming off the large breather from the cam cover.
http://i193.photobucket.com/albums/z...psjcdksikx.jpg
http://i193.photobucket.com/albums/z...psyrwrotaj.jpg
A new battery was fitted which gave me a reason to get my gauges all lit up.
http://i193.photobucket.com/albums/z...psgz3vp0ws.jpg
The whole interior z-let loom needed to be wired in and hidden under the dash, there’s a whole lot of wiring here!
http://i193.photobucket.com/albums/z...ps23kziqnx.jpg
Have bought some new tyres for the rear which will do a better job for potential track days, these are yoko ad08’s in a 185/55/15. Slightly narrower than the ao48 I have on the front which seem too wide for a reasonable stance on the rear.
http://i193.photobucket.com/albums/z...psq10a1fxq.jpg
I sent my intercooler off to James Middleton (jonlem) to have a couple of pipes welded to it and a map sensor port. Done a top job getting this sorted, will make things much neater in the bay as before I had to use a 90degree hose off the intercooler which was always a concern due to them rubbing the chassis legs.
http://i193.photobucket.com/albums/z...psk41whoun.jpg
http://i193.photobucket.com/albums/z...psyuffjkwr.jpg
James also sorted me out a new manifold, its an absolute piece of art. Made out of t304 schedule 10 pipes and 304 water jet cut flanges. Being a tart I thought id take some proper pictures of it before it gets used. Lol
http://i193.photobucket.com/albums/z...ps6bqiex47.jpghttp://i193.photobucket.com/albums/z...psvb5n7wur.jpg
http://i193.photobucket.com/albums/z...pswlupb76i.jpg
I had to replace the standard studs on the head to some shorter ones as they were too long and would foul the manifold. Got the manifold fitted along with the turbo.
http://i193.photobucket.com/albums/z...psnt4jhfac.jpghttp://i193.photobucket.com/albums/z...ps2griuczv.jpg
Trial fitted the intercooler and radiator for clearance and seems good, roughly 15/20mm of room.
http://i193.photobucket.com/albums/z...ps8zsviyqm.jpg
Having some spare stainless exhaust pieces kicking about I decided to use this for my down pipe, in reality I should use a 3inch down pipe along with a 3inch exhaust, but beggars cant be choosers as funds are rather tight at the minute. Added to these parts were a new flexi, flange and 90degree.
http://i193.photobucket.com/albums/z...pszzokicqn.jpg
One bodged down pipe ready to be welded up with a lambda bung for my wide band.
http://i193.photobucket.com/albums/z...psmujfcrbu.jpg
One heat wrapped down pipe, you’d never know it was a custom job. Lol
http://i193.photobucket.com/albums/z...pshpxwhmic.jpg
Had a nice delivery from the postman enabling me to crack on some more.
http://i193.photobucket.com/albums/z...ps65omurqm.jpg
As my radiator sat forward roughly an inch and a half the standard nova top hose wasn’t long enough, I didn’t want to cut and extend it as its another join as a potential week link. I ordered a corsa b xe/let conversion top hose which is slightly longer. Done the job perfect!
http://i193.photobucket.com/albums/z...pslzpzzyk5.jpg
A polished dipstick tube was fitted also as I stupidly cut my original up trying to fit that other manifold.
http://i193.photobucket.com/albums/z...ps4vzgdmei.jpg
10inch radiator fan fitted to replace my 2 7inch fans I used to run on the front, having moved the radiator forward was the cause of this but it was an easy fix.
I wasn’t sure where I was going to get the AFM and the filter to sit, I new I didn’t want it on show that much or pointing upwards across the boost pipe, using the bends I had left from making my down pipe I was able to use 2 90degrees to point it across the top of the gearbox. This is now painted black.
http://i193.photobucket.com/albums/z...pslgd7qylw.jpg
Dump valve fitting welded onto the boost pipe, kinda hides the DV out of the way for a more subtle look.
http://i193.photobucket.com/albums/z...psgdccocrg.jpg
MAP sensor wiring extended and MAP sensor fitted.
[URL=http://s193.photobucket.com/user/bachilds1988/media/DSC_0282_zpsbec7zttj.jpg.html]http://i193.photobucket.com/albums/z...psbec7zttj.jpg[/UR
I’ve also replaced the fuel sender gasket as it was leaking, doing this made me accidentally break a wire on the sender. This got soldered back on and then tested by filling up with some shell v-power nitro. It will get mapped on this for a slight gain in performance.
http://i193.photobucket.com/albums/z...ps5hc03r1k.jpg
Attempting to fit the slam panel back on showed a very snug fit with the manifold, its very unfortunate
that I had to cut it but needs must. Finished the edges off with some rubber trim.
http://i193.photobucket.com/albums/z...pscv6dthvy.jpg
Postie came round again to drop off some more pipes/hoses for the boost pipes.
http://i193.photobucket.com/albums/z...psa2g5m1ep.jpg
The turbo to intercooler pipe was fun to figure out as the original intention was to run it next to the down pipe but there wasn’t any room. Using the 2 90degree stainless bends gave me a useable setup.
http://i193.photobucket.com/albums/z...pscv0wi36x.jpg
Finishing up like this for the week end just past. Having put fuel in has a given me a couple of leeks on the fuel system. One being the second hand 044 pump and another on one of the braided lines. A new pump has been ordered and the braided line had a the union taken off and refitted.
http://i193.photobucket.com/albums/z...pshl2f5xul.jpg
http://i193.photobucket.com/albums/z...psm0x9fxhf.jpg
http://i193.photobucket.com/albums/z...psqigeiaac.jpg
More to come, thanks for looking.
Bruce
Looks great, I especially like the manifold. Also i like the catch tank hidden out the way like that.
Good work, Nick
Looks stunning, I like the fact it's a big power build but to a great standard, not just chopping and hacking everything up to get it all squeezed in, look forward to the next update.
Josh
Top work !
love it great work mate love the colour :)
cheers, it was the only real solution to get it out of the bay, I did debate having it in the scuttle area but ive got too much going on in there.Quote:
Originally Posted by totalnova
thanks josh.Quote:
Originally Posted by josh-sri
:dQuote:
Originally Posted by kevster
:thumb:Quote:
Originally Posted by novadave24
Looks bloody lovely. Great work.
http://i193.photobucket.com/albums/z...pscv6dthvy.jpg
cheers benn.
Some good news in that it now starts but doesn't like to stay running, have got a few fault codes to sort out which will hopefully solve this. Although it has a map currently in the ecu it may be a cause from this as some of my engine differs from what the map was specified to before I got the management.
Be nice to get it running correctly for retro rides.
Looking good! What power should you get with that setup?
Sorry for the late reply, aiming for a reasonable 350hp, the turbo starts to max out at 380ish so it'l be a nice figure for now. :)Quote:
Originally Posted by krobinson
An update is due, havnt got round to doing it just yet.
update
I'm finally getting round to giving this an update, although its not in depth and I have done loads of other bits in between, I've either forgot what I've done or its not that important.
first off, the car now runs. The map that was in the z-let ecu wouldn't let the engine run correctly due to it having different injectors and throttle body. I bought a set of 20 maps off ebay to let me run the car up to temp and check everything was ok. A standard map was no good, so I flashed in the last one which is spec'd for 360-380bhp apparently. The car now idles perfect, gets to temp, fan kicks and off etc. Getting it mapped will fine tune all of it hopefully.
I was never happy with my rose jointed gear linkage I made as it was too stiff on the joints, even lubing them up didn't help. I'm putting this down to buying expensive rose joints from a bearing supplier and wer'nt meant for the job I intended. I sold my old linkage and wanted to improve upon at least some of the sideways slop on my standard one, so I bought a pair of cheap rose joints off ebay. I made up only the sideways bar using the joints and threaded bar and fitted it to the linkage. I'm now very impressed with the slop that's been taken out, I'm tempted to do the rest of the linkage now I know where I went wrong with the first linkage.
With the manifold being so close to bonnet, I was unsure if over time it may melt the external paint. I bought some heat reflective material and stuck it on, hopefully it will have some effect on bonnet temps
Also purchased a new air filter for my 80mm vxr maf.
http://i193.photobucket.com/albums/z...psb3yzyfsb.jpg
http://i193.photobucket.com/albums/z...pspqcwnbii.jpg
After looking at the bay I was swaying towards tidying it up even more than it was, my z-let loom I fitted was bugging me slightly as I new I could shorten it some more and take away the length of loom that runs in front of the injectors. That way I could have the injector wiring come from under the manifold. With plenty of time to do it I stripped the loom back off and spent a few evenings shortening it.
I removed around 18inches from the hole centre of the loom, extended and shorted some sensor wiring. I also shortened the interior dash loom for the z-let management, there's minimal items that need to be run inside so it was easier to take more from this.
http://i193.photobucket.com/albums/z...pshizr9wui.jpg
finished products below.
http://i193.photobucket.com/albums/z...ps4isrmi8c.jpg
http://i193.photobucket.com/albums/z...pssijlweqo.jpg
I started to browse the articles section on here and had a good read through the rack removal while I situ. When the engine was out last time I replaced my original rack with another nova rack, this one didn't have any up an down movement in the bushes inside the rack, so I was happy. But, I couldn't help but want to find and fit a corsa epas 2.7 turn rack. I spoke to my local motor factor that I have an account with, giving them a reg from a corsa that had epas fitted. I explained I wanted a 2.7 turn rack and they sent me one out, only it was a corsa C rack, a phone call back to them and they then sent me out a 4 turn corsa B rack. Another phone call and they said they couldn't help me, nobody listed a 2.7 turn rack for a corsa b. It was proving hard to find one from online breakers as they all offered me a column as soon as I mentioned corsa and epas, disregarding me saying rack. I had a bit of luck and found one via a facebook friend.
old rack out from the side
http://i193.photobucket.com/albums/z...pslnr9x5s4.jpg
Stripped, painted and modified the column connector, both nova track rods/rack ends fitted too.
http://i193.photobucket.com/albums/z...psslxkx0go.jpg
http://i193.photobucket.com/albums/z...psrdxk08tk.jpg
Video of 2.7 turns.
http://i193.photobucket.com/albums/z...pslkli87l8.mp4
The next thing on the list was my brake pipes in the engine bay, I didn't like how they were routed and could benefit from positioning them differently.
http://i193.photobucket.com/albums/z...psef9cheub.jpg
Brake pipe and unions.
http://i193.photobucket.com/albums/z...pszt8ym7lh.jpg
All pipes made up.
http://i193.photobucket.com/albums/z...psphov8kcv.jpg
Painted, fitted and bled. Excuse the loose pipe on the left, I was using it to block my servo vacuum as I had the car running. lol
http://i193.photobucket.com/albums/z...psxbvxkn4u.jpg
Having the pipes off gave me the opportunity to paint my servo again and the master cylinder.
http://i193.photobucket.com/albums/z...pskur2kqa6.jpg
Got a bit of pussy action too.
http://i193.photobucket.com/albums/z...psec5avjqw.jpg
My front BCS (boost control solenoid, which is fitted at the rear) didn't have the one vacuum hose connected to anything, I thought it would be ok to vent to atmo, but I've since has some advice and been told to return it to the intake side of the turbo. I bought one of these silicone hose take offs for this as it was an easy fix rather than finding a suitable tube and weld it to the intake pipe I made.
http://i193.photobucket.com/albums/z...psjkcahv27.jpg
The red cesaros I have fitted are my only set of wheels since my softstars got stolen a few years ago, I've always wanted grey wheels but didn't want to commit to paint the red ones as I still quite like the colour.
I bought some plastidip in gunmetal grey, painted two wheels with one can(minus centre caps).
http://i193.photobucket.com/albums/z...psmypvbjmx.jpg
http://i193.photobucket.com/albums/z...psi4spddey.jpg
http://i193.photobucket.com/albums/z...psbr3vf2g1.jpg
The last pic does look quite dark and how I hoped it would come out, but it isn't. Its too light for my taste and doesn't match the trim.
http://i193.photobucket.com/albums/z...psymtox3f3.jpg
Plans are to bite the bullet and paint them with the grey the trim is in or BMW sparkling graphite. If you look at the pic right at the bottom of this post, the n/s wheel got covered in exhaust soot after I done an emissions test on a defender at work, the soot didn't really want to come off, although its made it darker and better than before. lol That's more the colour I would like.
http://i193.photobucket.com/albums/z...pspcfodybm.jpg
Things left to do:
Buy and fit a oil pressure gauge and rev counter. (the z-let tacho wire doesn't like a nova tacho)
Mapping which I hope I can get done in a couple months.
I was planning water meth but moneys tight at the moment after having a beautiful little girl.
Tidy up and paint any trim
paint my wheels grey
Remount my lift pump as its hella noisy with vibration.
plus anything else that rocks up.
In the mean time I have taken a couple proper photos of the car, so enjoy. :d
http://i193.photobucket.com/albums/z...ps7i2z2zmo.jpg
http://i193.photobucket.com/albums/z...psyhqobznt.jpg
thanks for looking
Bruce
I do like a smoothed GTE rear bumper; lots of work exhaust side, but biggest gain is from ditching the 90 degree abomination standard inlet. F28 should be loving all the torque!
...Those rods should come with arps?
Looking good, bays looking nice, brake lines are better routed too. kinda where i ran mine.
Stunning car.
Pure sex this car done so well
Yeh you had mentioned before, it will get addressed at some point.Quote:
Originally Posted by BRoadGhost
I had the option to add arp's, but as i had some i thought that would be ok, i didnt know they were differant thread.
Thanks benn, i remember seeing yours at pvs a couple years ago, they've always bugged me.Quote:
Originally Posted by Benn
Thanks alot. :thumb:Quote:
Originally Posted by nova_stee