Just realised it's nearly 6 months since last post - where does the time go.
Well, I've got to admit that after the mad session I last had on the car back in May when the weather turned for the better, I decided to give it a rest as it was so hot. Then I went on holiday in August and cracked/broke/strained rib(s) (unknown as NHS didn't Xray, and they still hurt!!!!) so not had a chance to do anything. And very busy at work.
One nearly interesting thing is, that because I nearly, bought another project. I didn't, but nearly did. Still quite keen for it to happen, but hey....
Anyway, I probably won't get a chance to work on the car till Christmas break, so there prob won't be another update till new year, so I wish you all a Happy both now.
Simon
Saturday 21 November 2009
Wednesday 27 May 2009
Big post, perhaps
OK, Went to Car Builder Solutions on Saturday and got their usual helpful service (yep, I'd recommend them to anyone), and got my nice new petrol cap, hose and tank connector/adaptor thingy.
The tank adaptor is a flat piece of ally with a hole in it with an ally tube welded on. The idea is to use existing cap (which in my case was bolted directly to tank) to mark holes on adaptor, and use existing tank holes to attach it with.
My only criticism of the adaptor is the thickness of the plate part, which while fine for strength but didn't allow me to countersink the setscrews into it.
Simpe answer there was to cut the neck off old cap, and turn it into a big washer with countersunk holes already in.
As I was using setscrews, I had to have nylocs on the inside of tank, and the "tool" resting over the tank strap is my Heath Robinson affair, consisting of a socket the right size and a length of flattened tube welded to it, and bent so that it fits through filler tube without dropping nyloc. Worked a treat.
The next pic is of the new ally back panel, already cut approximately to shape, with the lower edge bent ready to rivet to rear lower tube and with filler hole roughly cut.
The next job was rivetting panel on the bottom chassis tube then starting the tiresome job of folding the top over chassis tube, then bending panel around the corner. This was quite difficult as I wanted to retain the shape I had made on the fibreglass panel, being a square corner at the bottom and a radiused on at the top.
Which eventually ended up like like
Yes, they are dents in the ally at the top. It's what happens when the G clamp slips.
On a slightly lighter note; whe I was at CBS, I was perusing their display boards and spotted a "Start" button. So a bit of gratuitous spending was called for. It's also served the purpose of filling a hole left by the fan override switch I'd left in the dash! Two gauge sized holes to fill yet!
On a slightly lighter note; whe I was at CBS, I was perusing their display boards and spotted a "Start" button. So a bit of gratuitous spending was called for. It's also served the purpose of filling a hole left by the fan override switch I'd left in the dash! Two gauge sized holes to fill yet!
It's not wired in, but the "loom" is made and just needs plugging in.
Next pic is of one of the rear arches which are going to be reprayed by a friend (Phil at HRC) who does it for a living. I'm just doing the preparation work to try and keep costs down. Yes, that's filler in all the stonechips! Both rear arches are the same.
Next job I had to do was get the roll bar brackets welded into place, so I removed all the bits I'd installed and had to weld some spacer pieces to roll bar tubes that went into chassis. For a brief moment I didn't think it was going to go back in as I took a guess on how much to widen by. Fortunately, it's a nice snug fit.
Once they were welded in, it was a case of welding top tubes into place. Unfortunately my mig skill leave a little to be desired on the neatness front, so a soon as car is on the road, I'll take it to work and go over the welds with the tig - which will be neat!
Other things I've started doing are the new ally side panels. I'd hammered the top over on a couple of the sides - which took about 1.5 hrs, with box section clamped over, but it looked rubbish. The I remembered Phil has a sheet folder so paid him a visit...
so, I'm going to redo the ones I already half made. I'm also going to lose the wood/vinyl interior and do that in ally too!
Anyway, progress is being made, so till next update, here's a gratuitous pic of a 3.9 Rover V8 with my modified exhausts:D
Till then
Simon
Thursday 21 May 2009
Now it's getting ridiculous!
Having made a decision over the last few weeks that I would be replacing the side panels with new ally, and that the back boot panel might as well be in ally too (rather than fibreglass), I ordered three sheets of 2.5m x 1.25m x 1.5mm ally yesterday.
That meant that I had to get organised in the order that work was to happen - like a list of jobs, and when they needed to be done.
Tonight that list included removing tail lights, rear arches and the boot panel. And I succeeded, and I made a template of the panel ready to transfer to the ally. So far so good, ahead of schedule.
I've spoken to a friend who's going to do the painting, just to find out what I need to do finish wise, in preparation so just need to get those bits of plastic that I can give him (off the car) filled, sanded and primed.
If I can stick to my schedule, I'm hoping to have the rear panel and both replacement side panels in place, all plastic panels ready for topcoat and the roll bar all welded, painted and fitted, the exhausts back on and plastic panels to Phil for painting by Monday pm.
Hopefully he'll be able to do them next week, so I'll have them back on the car by weekend of 30/5 and I'll just need to get the bonnet - yes, I'm going to make that from ally too - fitted!!!
Other changes I'm hoping to make include moving the fuel cap to the new ally back panel as it was a major inconvenience trying to get the fuel filler into the boot without chucking petrol everywhere and I want some new rear light assemblies to replace the budget "trailer" lights I had.
A couple more minor jobs like fi the horn, then off for ticket and tax:D
More on Monday with pics (yeah really!).
Till then
Simon
That meant that I had to get organised in the order that work was to happen - like a list of jobs, and when they needed to be done.
Tonight that list included removing tail lights, rear arches and the boot panel. And I succeeded, and I made a template of the panel ready to transfer to the ally. So far so good, ahead of schedule.
I've spoken to a friend who's going to do the painting, just to find out what I need to do finish wise, in preparation so just need to get those bits of plastic that I can give him (off the car) filled, sanded and primed.
If I can stick to my schedule, I'm hoping to have the rear panel and both replacement side panels in place, all plastic panels ready for topcoat and the roll bar all welded, painted and fitted, the exhausts back on and plastic panels to Phil for painting by Monday pm.
Hopefully he'll be able to do them next week, so I'll have them back on the car by weekend of 30/5 and I'll just need to get the bonnet - yes, I'm going to make that from ally too - fitted!!!
Other changes I'm hoping to make include moving the fuel cap to the new ally back panel as it was a major inconvenience trying to get the fuel filler into the boot without chucking petrol everywhere and I want some new rear light assemblies to replace the budget "trailer" lights I had.
A couple more minor jobs like fi the horn, then off for ticket and tax:D
More on Monday with pics (yeah really!).
Till then
Simon
Monday 18 May 2009
Tidying up...
...from where I left off last week is what I've been up to.
As I said, the top radiator hose needed fitting and a couple of minor hoses (eg the plenum heater hoses) needed "t-ing" into what was to become the top hose.
The slight headache came when I was looking at the (original) heater hoses. On the SD1 engine, these run under the inlet manifold to the rear of engine, so I connected one straight to the header tank and the other was blanked off. On the Range Rover engine, they are both at the front of the engine, and would need blocking, but that would have created air locks (as they are both vertical).
In a moment of pure genius, I had the bright idea of getting a piece of steel tube, and welding two "t's" to go into the tops of hoses, then running that along the engine, by the injectors, to the rear of the engine, then (with a reducer) to a flexi rubber pipe to header tank. Simple!!! So I filled the system with water/antifreeze and ran the engine for about 10 minutes on Sunday.
That went well in as much as I didn't have any leaks, but it did remind me to do two things. The first was to check for oil pressure (which I have) and that I need to get the fan wired up.
Well, it's Monday as I write this and the fan was wired up earlier this evening and now works fine.
The ecu is now in residence so to speak, but I think I'll be putting a cover of sorts over that for security.
I can't remember if I mentioned that the engine wouldn't turn over on the key, but only with me shorting the starter motor terminals with a screwdriver. Well, that turned out to be a wire in the wrong place! Easy but time consuming fix, and engine now starts on the key.
There are a couple of little jobs that I need to do like wire in the tacho, but they aren't required for the MOT, so they may have to wait, as I'm quite keen on getting the bonnet done. Once that's done, I'll be ordering some more ally sheet to redo side panels and the boot (which is fibreglass at the mo). Had a chat with a friend this eveing who paints for a living and I may have him paint the car. Need to find out what sort of finish I need to get to first. Even wife was keen on it being pro painted when I mentioned it:D
Anyway, I doubt I'll do much on the car toomorrow (Tuesday) as I'll be swimming in the evening, but hopefully by the end of this (bank holiday) weekend I'll have the bonnet done and have some pics for you:D
Till Monday then...
Simon
As I said, the top radiator hose needed fitting and a couple of minor hoses (eg the plenum heater hoses) needed "t-ing" into what was to become the top hose.
The slight headache came when I was looking at the (original) heater hoses. On the SD1 engine, these run under the inlet manifold to the rear of engine, so I connected one straight to the header tank and the other was blanked off. On the Range Rover engine, they are both at the front of the engine, and would need blocking, but that would have created air locks (as they are both vertical).
In a moment of pure genius, I had the bright idea of getting a piece of steel tube, and welding two "t's" to go into the tops of hoses, then running that along the engine, by the injectors, to the rear of the engine, then (with a reducer) to a flexi rubber pipe to header tank. Simple!!! So I filled the system with water/antifreeze and ran the engine for about 10 minutes on Sunday.
That went well in as much as I didn't have any leaks, but it did remind me to do two things. The first was to check for oil pressure (which I have) and that I need to get the fan wired up.
Well, it's Monday as I write this and the fan was wired up earlier this evening and now works fine.
The ecu is now in residence so to speak, but I think I'll be putting a cover of sorts over that for security.
I can't remember if I mentioned that the engine wouldn't turn over on the key, but only with me shorting the starter motor terminals with a screwdriver. Well, that turned out to be a wire in the wrong place! Easy but time consuming fix, and engine now starts on the key.
There are a couple of little jobs that I need to do like wire in the tacho, but they aren't required for the MOT, so they may have to wait, as I'm quite keen on getting the bonnet done. Once that's done, I'll be ordering some more ally sheet to redo side panels and the boot (which is fibreglass at the mo). Had a chat with a friend this eveing who paints for a living and I may have him paint the car. Need to find out what sort of finish I need to get to first. Even wife was keen on it being pro painted when I mentioned it:D
Anyway, I doubt I'll do much on the car toomorrow (Tuesday) as I'll be swimming in the evening, but hopefully by the end of this (bank holiday) weekend I'll have the bonnet done and have some pics for you:D
Till Monday then...
Simon
Sunday 10 May 2009
Hurrah!
Ok, so it's not going to be a very long post, as I only did a little bit on the car today, but what a bit!
Started off this morning looking at the wiring - yeah, in complete contrast to where the wiring was in the list of jobs to do.
Anyway, firstly looked at the wires around the coil and sorted those out, then figured I needed a 6.8k Ohm resistor in the wire between a/f meter and coil, but didn't have one - except the one that goes to the speed signal thingy, which a) is supposed to limit the speed in the Range Rover and b) wasn't being used because of a)!
Anyway, sorted those out, then looked at the wires for the ecu, and if you look in all the blurb on the net it says the ecu has a brown wire for permanent live feed, also found it may be brown/orange - could I find them?! Well, no not as a direct connection!
Anyway, had a look through the bundle of wires and figured that it was another orange/? wire (yeah forgot for the mo!) and there is a white wire from coil that's needs connecting to a switched white wire from ecu.
So, connected that lot up, carefully, and thought I'd turn it on and see what happens.
Bloody hell, it started, but ran really rough, very little throttle control, high tickover (about 2500 rpm), couldn't close throttle any further etc.
Started thinking; oh dear.
Then, when I looked at the airflow meter, the bulb went of. I thought that I'd left an old rag in the plenum inlet to prevent ingress of dirt, dust, spanners, nuts and bolts etc.
Quickly removed hose, removed rag, reconnected hos and tried again.
Wow. Started instantly, ran with a slightly lumpy tickover, but instant throttle response. It occurred to me later while looking for my allen keys, that lumpy tickover is due to a couple of airleaks which I knew of, but forgot to do anything about.
Next job I started today was getting the rad back in, which involved hacking the bottom hose around a bit, but that's now back on, just the top hose to do, which I'll do over a few evenings.
And I started tidying the wiring, ready for a permanent fix.
All in all, I'd say I'm very pleased on the day's progress.
More next weekend hopefully
Till then
Simon
Started off this morning looking at the wiring - yeah, in complete contrast to where the wiring was in the list of jobs to do.
Anyway, firstly looked at the wires around the coil and sorted those out, then figured I needed a 6.8k Ohm resistor in the wire between a/f meter and coil, but didn't have one - except the one that goes to the speed signal thingy, which a) is supposed to limit the speed in the Range Rover and b) wasn't being used because of a)!
Anyway, sorted those out, then looked at the wires for the ecu, and if you look in all the blurb on the net it says the ecu has a brown wire for permanent live feed, also found it may be brown/orange - could I find them?! Well, no not as a direct connection!
Anyway, had a look through the bundle of wires and figured that it was another orange/? wire (yeah forgot for the mo!) and there is a white wire from coil that's needs connecting to a switched white wire from ecu.
So, connected that lot up, carefully, and thought I'd turn it on and see what happens.
Bloody hell, it started, but ran really rough, very little throttle control, high tickover (about 2500 rpm), couldn't close throttle any further etc.
Started thinking; oh dear.
Then, when I looked at the airflow meter, the bulb went of. I thought that I'd left an old rag in the plenum inlet to prevent ingress of dirt, dust, spanners, nuts and bolts etc.
Quickly removed hose, removed rag, reconnected hos and tried again.
Wow. Started instantly, ran with a slightly lumpy tickover, but instant throttle response. It occurred to me later while looking for my allen keys, that lumpy tickover is due to a couple of airleaks which I knew of, but forgot to do anything about.
Next job I started today was getting the rad back in, which involved hacking the bottom hose around a bit, but that's now back on, just the top hose to do, which I'll do over a few evenings.
And I started tidying the wiring, ready for a permanent fix.
All in all, I'd say I'm very pleased on the day's progress.
More next weekend hopefully
Till then
Simon
Monday 4 May 2009
Getting there!!
Another quickish update I'm afraid.
Didn't quite get the whole (long) weekend on the car, but I've had a good few hours today and a little time yesterday!
You'll recall the list that needed doing went something like this:
Need to make a bracket for the air flow meter
Modify exhausts as no turbo's to connect pipes anymore
Wiring will need sorting
Sort the bonnet out
Fit the radiator and plumb in
Paint the rest of the bodywork
Modify the alternator bracket
Get roll bar sorted!
Throttle linkage (which I'd forgotten)
Well the exhausts are all connected from manifold to tail pipe on both sides, so that's one of the bigger jobs done. I've also made the mounting bracket for the airflow meter - not a pretty site, but hey, just won't open the bonnet! The other successes for the day were getting throttle linkage connected up and modifying the alternator brackets. So now throttle works and alternator is back in place.
List now looks like (in order I'll do them, I think):
Fit the radiator and plumb in
Sort the bonnet out
Get roll bar sorted
Wiring
Paint the rest of the bodywork
Let's face it, fitting the radiator isn't going to take too long, possible an hour or two depending on pipework route, and how it all fits under the bonnet - it'll be slightly different than turbo route as I had the coil packs and didn't need to go over dizzy, which I now do.
The bonnet I should be able to do in a day - a fairly intensive day, and likewise sorting the rest of bodywork a similar time. The rollbar should take about four or five hours.
Still to sort the wiring, which I keep looking at and getting nowhere. It's a bit irritating really as whereever you look on the web it only needs about three wires. Can I find the elusive three?
Anyway, going for a nice cup of tea now, and will have a little more time on car tonight and tomorrow evenings, then next weekend hopefully.
Maybe more pics midweek.
Till then
Simon
Didn't quite get the whole (long) weekend on the car, but I've had a good few hours today and a little time yesterday!
You'll recall the list that needed doing went something like this:
Need to make a bracket for the air flow meter
Modify exhausts as no turbo's to connect pipes anymore
Wiring will need sorting
Sort the bonnet out
Fit the radiator and plumb in
Paint the rest of the bodywork
Modify the alternator bracket
Get roll bar sorted!
Throttle linkage (which I'd forgotten)
Well the exhausts are all connected from manifold to tail pipe on both sides, so that's one of the bigger jobs done. I've also made the mounting bracket for the airflow meter - not a pretty site, but hey, just won't open the bonnet! The other successes for the day were getting throttle linkage connected up and modifying the alternator brackets. So now throttle works and alternator is back in place.
List now looks like (in order I'll do them, I think):
Fit the radiator and plumb in
Sort the bonnet out
Get roll bar sorted
Wiring
Paint the rest of the bodywork
Let's face it, fitting the radiator isn't going to take too long, possible an hour or two depending on pipework route, and how it all fits under the bonnet - it'll be slightly different than turbo route as I had the coil packs and didn't need to go over dizzy, which I now do.
The bonnet I should be able to do in a day - a fairly intensive day, and likewise sorting the rest of bodywork a similar time. The rollbar should take about four or five hours.
Still to sort the wiring, which I keep looking at and getting nowhere. It's a bit irritating really as whereever you look on the web it only needs about three wires. Can I find the elusive three?
Anyway, going for a nice cup of tea now, and will have a little more time on car tonight and tomorrow evenings, then next weekend hopefully.
Maybe more pics midweek.
Till then
Simon
Sunday 26 April 2009
Quick update on not-a-lot!
Right, very quickly, as there isn't much to tell.
Went to Detling Kitcar Show and quite enjoyed that. Managed to get twenty stainless steel bends from 38mm tubing for only £40. When you consider most places seem to charge anything up to £20 per bend, you can see why I was quite excited:D
Anyway, the point of buying the bends was to build new exhaust manifolds, but having since spent a couple of evenings knocking up new manifolds and not being too impressed with the rushed results, I've since decided to use the Range Rover manifolds and make some link tubes, which should work better, look worse and save a lot of time.
Now, I still have a lot of work to do on the car, but this weekend coming I've "told" the wife I'm spending all weekend (including the Bank Holiday Monday) sorting the car out. And she's agreed:D
If you recall the work needed was this
Need to make a bracket for the air flow meter - which will face rearward
Modify exhausts as no turbo's to connect pipes anymore
Wiring will need sorting
Sort the bonnet out
Fit the radiator and plumb in
Paint the rest of the bodywork
Modify the alternator bracket
Get roll bar sorted!
The car also needs an MOT and tax, but if I can get that lot done next weekend, we may have T&T the week after:D
Bigger, hopefully more positive post a week on Monday!
Simon
Went to Detling Kitcar Show and quite enjoyed that. Managed to get twenty stainless steel bends from 38mm tubing for only £40. When you consider most places seem to charge anything up to £20 per bend, you can see why I was quite excited:D
Anyway, the point of buying the bends was to build new exhaust manifolds, but having since spent a couple of evenings knocking up new manifolds and not being too impressed with the rushed results, I've since decided to use the Range Rover manifolds and make some link tubes, which should work better, look worse and save a lot of time.
Now, I still have a lot of work to do on the car, but this weekend coming I've "told" the wife I'm spending all weekend (including the Bank Holiday Monday) sorting the car out. And she's agreed:D
If you recall the work needed was this
Need to make a bracket for the air flow meter - which will face rearward
Modify exhausts as no turbo's to connect pipes anymore
Wiring will need sorting
Sort the bonnet out
Fit the radiator and plumb in
Paint the rest of the bodywork
Modify the alternator bracket
Get roll bar sorted!
The car also needs an MOT and tax, but if I can get that lot done next weekend, we may have T&T the week after:D
Bigger, hopefully more positive post a week on Monday!
Simon
Friday 10 April 2009
Another four weeks passes!
Well, Detling starts tomorrow, and over the last four weeks I have made (and very nearly finished) a towbar bracket mounted bike rack!
It's quite good, honestly:D Car has detatchable towball, and the bike rack fits in the socket. Held in place with bolt and even with bikes on, I'll be able to open the boot. Oooooo
So, as you may have guessed, with the evening work, swimming and making bike rack, and with Easter weekend being Detling, I've managed to get absolutely nothing done to the car in a MONTH!!!!!!!
At this rate, it'll be three years car will have been off the road and another summer gone!
Never mind I hear you say, Easter weekend; it's four days off. Well, you'd be right, but I spent all day painting the boys bedroom yesterday (Friday) and more today, Detling on Sunday am, lunch with Mother/Bro, wife and kids then might test new lawn mower. Oh yeah, also refaced all the fascia boards a week or two back.
Might get out there Monday, if I don't go into work.
Might not go to Detling which will p me off slightly as I've been looking forward to it for a good few months.
Anyway, if I get anything done, I'll let you know, but don't hold your breath.
It's quite good, honestly:D Car has detatchable towball, and the bike rack fits in the socket. Held in place with bolt and even with bikes on, I'll be able to open the boot. Oooooo
So, as you may have guessed, with the evening work, swimming and making bike rack, and with Easter weekend being Detling, I've managed to get absolutely nothing done to the car in a MONTH!!!!!!!
At this rate, it'll be three years car will have been off the road and another summer gone!
Never mind I hear you say, Easter weekend; it's four days off. Well, you'd be right, but I spent all day painting the boys bedroom yesterday (Friday) and more today, Detling on Sunday am, lunch with Mother/Bro, wife and kids then might test new lawn mower. Oh yeah, also refaced all the fascia boards a week or two back.
Might get out there Monday, if I don't go into work.
Might not go to Detling which will p me off slightly as I've been looking forward to it for a good few months.
Anyway, if I get anything done, I'll let you know, but don't hold your breath.
Sunday 15 March 2009
Done a bit...
Managed to get some time on the car today, which was nice.
List of jobs that needed doing prior to today's play around were:
a) Fuel lines - at the rear I needed to bend the pipe (for fuel return) to shape, and clip to chassis, and clip fuel line in the transmission tunnel.
b) The existing fuel feed (in boot, by pump) has the pressure regulator fitted to it, which will need removing and the "t" piece removing, as pressure reg incorporated on fuel rail of this engine.
c) In the engine compartment, I'll need to get the fuel lines connected to the fuel rail, and then test system - ie turn on ignition and fuel pump and check for leaks.
d) Also need to make a bracket for the air flow meter - which will face rearward, and modify exhausts as no turbo's to connect pipes anymore.
e) Wiring will need sorting, which I'm not looking forward to, then
f) I need to sort the bonnet out,
g) fit the radiator and plumb in, and
h) paint the rest of the bodywork!
i) modify the alternator bracket
Oh, and get roll bar sorted!
Not too much then.
So what did I do today?
Well, got up at 7.30, straight to the pool for a quick 80 (ish) lengths, home at 9.45, find wife and boys still relaxing, so feed boys, get washing on line, wash up breakfast stuff (all adds up to good garage time:D), then have major tidy up in garage.
And at about midday, I finally started working on the car. It was quite productive - I got a) to c) done, including the leak test. That might come in for some more testing and/or modification before I go on the road, though I'm sure all's ok.
Obviously, I'd liked to have got a bit further, but you know what it's like. Want to do something - first job of the day and........ spent 20 minutes looking for my hacksaw. Rest of day wasn't quite as bad, but I had tidied up, so was entitled not to be able to find anything. For what it's worth the hacksaw was under the bonnet!
Also removed the Emerald ECU/turbo and LC1 (lambda) gauges. I may replace the 13cux ecu with the Emerald at some point, but not just yet.
I'm going to be working Monday and Wedneday evenings and swimming on Tuesday, so won't get much chance to work on car, though I may be able to modify the alternator bracket as it sits about half inch too far forward and doesn't align with the pulleys; I'll also try and get the airflow meter bracket made, maybe fitted. While tidying the garage I found the Range Rover alternator tensioner bracket - which will help!
Anyway, next Sunday, I'll be out for the day Chief Marshalling the London to Brighton Pioneer Run (veteran bikes), so will will try and do some work on car on Saturday afternoon.
Till then
Simon
List of jobs that needed doing prior to today's play around were:
a) Fuel lines - at the rear I needed to bend the pipe (for fuel return) to shape, and clip to chassis, and clip fuel line in the transmission tunnel.
b) The existing fuel feed (in boot, by pump) has the pressure regulator fitted to it, which will need removing and the "t" piece removing, as pressure reg incorporated on fuel rail of this engine.
c) In the engine compartment, I'll need to get the fuel lines connected to the fuel rail, and then test system - ie turn on ignition and fuel pump and check for leaks.
d) Also need to make a bracket for the air flow meter - which will face rearward, and modify exhausts as no turbo's to connect pipes anymore.
e) Wiring will need sorting, which I'm not looking forward to, then
f) I need to sort the bonnet out,
g) fit the radiator and plumb in, and
h) paint the rest of the bodywork!
i) modify the alternator bracket
Oh, and get roll bar sorted!
Not too much then.
So what did I do today?
Well, got up at 7.30, straight to the pool for a quick 80 (ish) lengths, home at 9.45, find wife and boys still relaxing, so feed boys, get washing on line, wash up breakfast stuff (all adds up to good garage time:D), then have major tidy up in garage.
And at about midday, I finally started working on the car. It was quite productive - I got a) to c) done, including the leak test. That might come in for some more testing and/or modification before I go on the road, though I'm sure all's ok.
Obviously, I'd liked to have got a bit further, but you know what it's like. Want to do something - first job of the day and........ spent 20 minutes looking for my hacksaw. Rest of day wasn't quite as bad, but I had tidied up, so was entitled not to be able to find anything. For what it's worth the hacksaw was under the bonnet!
Also removed the Emerald ECU/turbo and LC1 (lambda) gauges. I may replace the 13cux ecu with the Emerald at some point, but not just yet.
I'm going to be working Monday and Wedneday evenings and swimming on Tuesday, so won't get much chance to work on car, though I may be able to modify the alternator bracket as it sits about half inch too far forward and doesn't align with the pulleys; I'll also try and get the airflow meter bracket made, maybe fitted. While tidying the garage I found the Range Rover alternator tensioner bracket - which will help!
Anyway, next Sunday, I'll be out for the day Chief Marshalling the London to Brighton Pioneer Run (veteran bikes), so will will try and do some work on car on Saturday afternoon.
Till then
Simon
Thursday 5 March 2009
Slo go again
Another couple of weeks of not much progress.
I've sort of sorted the engine compartment hard fuel lines, just need to get some soft line the right size, then "p-clip" it in the transmission tunnel .
Also started hacking the bonnet around; well most of the hacking is done, I just need to get on with the detail and filling/reshaping.
Really busy at work at the mo, so not much chance to get on with car.
Never mind. Yes, again I'm getting fed up with lack of progress.
Hopefully, next post will be on a more positive note, and some work will have been done on the car.
Simon
I've sort of sorted the engine compartment hard fuel lines, just need to get some soft line the right size, then "p-clip" it in the transmission tunnel .
Also started hacking the bonnet around; well most of the hacking is done, I just need to get on with the detail and filling/reshaping.
Really busy at work at the mo, so not much chance to get on with car.
Never mind. Yes, again I'm getting fed up with lack of progress.
Hopefully, next post will be on a more positive note, and some work will have been done on the car.
Simon
Sunday 22 February 2009
Quick post!
I haven't had much time on the car this week, even though I was hoping to have made some more progress.
I swapped over the starter motors (from turbo engine to this one) as that already on new engine had a slightly different layout which resulted in the solenoid sticking out too far towards exhaust. Putting the other on on has given me another couple of inches. Which is nice.
I also got round to putting the alternator bracket on (again from the old engine) as I want it nice and low and out of the way, but as usual, there's always a spanner in the works. In this case , it's the water pump/timing chain cover. I think it's one of them intermediate type covers, but the result is that the alternator and waterpump/crank pullies don't line up. I'll take the easiest fix, and remove half an inch from the alternator bracket. Using the new engine's pullies actually gives me about and extra inch of space at front of engine, so that might help for something.
I've plugged the loom into all the sensors on the engine, but have so much wiring, I'm going to have to strip the covering off the loom and go through it to see what I need and what I don't.
I fitted the turbo exhausts to the new engine, but might try and use the new engines manifolds as they will probably flow better.
I'd like to say I hope to make a bit more progress this week, but we have a bit of a rush coming up at work, so I'll be working Monday and Wednesday evenings, swimming on Tuesday which might leave Thurs/Friday if I'm not too tired.
Anyway, till next weekend, I guess
Simon
I swapped over the starter motors (from turbo engine to this one) as that already on new engine had a slightly different layout which resulted in the solenoid sticking out too far towards exhaust. Putting the other on on has given me another couple of inches. Which is nice.
I also got round to putting the alternator bracket on (again from the old engine) as I want it nice and low and out of the way, but as usual, there's always a spanner in the works. In this case , it's the water pump/timing chain cover. I think it's one of them intermediate type covers, but the result is that the alternator and waterpump/crank pullies don't line up. I'll take the easiest fix, and remove half an inch from the alternator bracket. Using the new engine's pullies actually gives me about and extra inch of space at front of engine, so that might help for something.
I've plugged the loom into all the sensors on the engine, but have so much wiring, I'm going to have to strip the covering off the loom and go through it to see what I need and what I don't.
I fitted the turbo exhausts to the new engine, but might try and use the new engines manifolds as they will probably flow better.
I'd like to say I hope to make a bit more progress this week, but we have a bit of a rush coming up at work, so I'll be working Monday and Wednesday evenings, swimming on Tuesday which might leave Thurs/Friday if I'm not too tired.
Anyway, till next weekend, I guess
Simon
Sunday 15 February 2009
Pics, pics and er, pics
Ok, as promised, a quick update in pictoral form - and apologies in advance, some are a bit rubbish!
This is a pic of how far I got installing the new fuel return line. You have to bear in mind the aggro it took to get this baby down the transmission tunnel and my reluctance to start bending it (by hand) to the correct shape. I'm sure it'll be ok once I get started though.
As you can see, this is a pic of the engine, now in situ. Notice it still has the three inch high flame trap - which won't fit under the bonnet. Easy fix, as I have a flat takeoff on the other engine that I'll fit to this engine, which will allow me to lay this one down, and out of the way.
I didn't get a chance to do any work on the car today - needed to get my swimming fix in, then took some rubbish to the dump, then went out for lunch at the sailing club and finally, got home and cleaned the inside of my bus:
which took the best part of 2 hours!!!!! Well, theres a lot to clean:D
Anyway, back to toy car, this (rather dark/dull and out of focus) pic was taken the evening before the new engine installation and the lighting is quite poor. It's only an empty engine bay, so hardly worth getting excited about.
This is a pic of how far I got installing the new fuel return line. You have to bear in mind the aggro it took to get this baby down the transmission tunnel and my reluctance to start bending it (by hand) to the correct shape. I'm sure it'll be ok once I get started though.
As you can see, this is a pic of the engine, now in situ. Notice it still has the three inch high flame trap - which won't fit under the bonnet. Easy fix, as I have a flat takeoff on the other engine that I'll fit to this engine, which will allow me to lay this one down, and out of the way.
Here' a pic of the engine in situ, from the front - thinking my bonnet is going to need quite a bit of hacking around to get that plenum to fit, and the airflow meter and the air filter:D
Anyway, that little lot should be enough to keep you amused till next weekend, when I hope to have
a) done the return fuel line - meaning bent to shape, connected to fuel tank and "P-clipped" into place
b) got the fuel injection pipes connected to fuel line
c) got ecu and engine wiring into place
d) got the alternator mounted
e) maybe one or two other jobs too.
Detling KitCar Show in about 10 weeks!
Till next time
Simon
Saturday 14 February 2009
It's in, it's in, it's in...mostly
Just a quick note to let you know how today went - will be more tomorrow, but mostly pics.
First thing that I needed to do this morning was to get a new gasket for the oil pump cover remote take off.
Jump in car, drive to local (non franchised) Land Rover showroom/service and parts place) and ask if they have a gasket. Bear in mind this engine appears in about 80% of the vehicles they deal with, and ...no, they haven't got one!
Jump in car, drive to PWMC (local spares shop mentioned elsewhere on here) and see one of the folks in there. Ask if they have any gasket paper, to be presented with a roll of the stuff.
Paul then came over to give me a hand for the day, and once the pump cover had been swapped over and the return fuel line loosely fitted down tunnel, it was time to chuck in the engine. With a little wiggle here and there, and the removal of the LR positioned alternator and the water pump tensioner wheel (which won't be needed as alternator will be repositioned back to bottom left of engine), we eventually got the engine in the car.
Plenum sits a fair bit higher than old one (which had had about an inch machined off), so I'll have my work cut out over the next couple of weeks getting the bonnet modified (yet again!), sorting the plumbing and the wiring.
Then paint, MOT and tax and away we go.
As mentioned earlier, another post tomorrow which will be mostly pics.
Simon
First thing that I needed to do this morning was to get a new gasket for the oil pump cover remote take off.
Jump in car, drive to local (non franchised) Land Rover showroom/service and parts place) and ask if they have a gasket. Bear in mind this engine appears in about 80% of the vehicles they deal with, and ...no, they haven't got one!
Jump in car, drive to PWMC (local spares shop mentioned elsewhere on here) and see one of the folks in there. Ask if they have any gasket paper, to be presented with a roll of the stuff.
Paul then came over to give me a hand for the day, and once the pump cover had been swapped over and the return fuel line loosely fitted down tunnel, it was time to chuck in the engine. With a little wiggle here and there, and the removal of the LR positioned alternator and the water pump tensioner wheel (which won't be needed as alternator will be repositioned back to bottom left of engine), we eventually got the engine in the car.
Plenum sits a fair bit higher than old one (which had had about an inch machined off), so I'll have my work cut out over the next couple of weeks getting the bonnet modified (yet again!), sorting the plumbing and the wiring.
Then paint, MOT and tax and away we go.
As mentioned earlier, another post tomorrow which will be mostly pics.
Simon
Friday 13 February 2009
New Dawn starts later.. like morning!
Last night (being Thursday, this being Saturday morning - with me so far!), I attached the flywheel and clutch to the new engine and removed the engine mountings from 3.9 engine.
This evening (being Friday:) I started cleaning up the remote filter housing ready for installation to new engine and guess what?
The pressure release valve was sticking. Needless to say, I'm quite relieved in a way that it was something simple. That solves the low pressure issue. Still, it's fairly irrelevant now, I'll just have to keep an eye on oil pressure. Cleaned it all up and ressembled it and it seems ok. Fingers crossed.
When the turbo engine goes into the next project, the chassis will be designed around it, so I can revert, for the most part, to standard production items - such as the orginal filter takeoff.
Anyway, I got the new engine home and it's sitting on the garage floor. First thing in the morning, I have to go and get a new oil pump gasket, then swap over the remote takeoff, drain engine oil and remove some of the useless bits of engine compartment ventilation and side mounted air filter housings.
I'll also need to get some "P-clips" and get the other fuel line in (going down the transmission tunnel, next to existing one) while engine is still out - no I haven't done it yet.
When that's all done, we (a friend is coming over to help) can get the engine in.
Then starts the wiring rehash, locating the ecu and airflow meter etc etc. I know I could use the Emerald, but I'm going to stick with the Land Rover bits as far as possible.
Anyway, won't say anymore, or there'll be no point reading the next exciting instalment.
Will there:D
Till tomorrow (or this evening, as the case may be)
Simon
This evening (being Friday:) I started cleaning up the remote filter housing ready for installation to new engine and guess what?
The pressure release valve was sticking. Needless to say, I'm quite relieved in a way that it was something simple. That solves the low pressure issue. Still, it's fairly irrelevant now, I'll just have to keep an eye on oil pressure. Cleaned it all up and ressembled it and it seems ok. Fingers crossed.
When the turbo engine goes into the next project, the chassis will be designed around it, so I can revert, for the most part, to standard production items - such as the orginal filter takeoff.
Anyway, I got the new engine home and it's sitting on the garage floor. First thing in the morning, I have to go and get a new oil pump gasket, then swap over the remote takeoff, drain engine oil and remove some of the useless bits of engine compartment ventilation and side mounted air filter housings.
I'll also need to get some "P-clips" and get the other fuel line in (going down the transmission tunnel, next to existing one) while engine is still out - no I haven't done it yet.
When that's all done, we (a friend is coming over to help) can get the engine in.
Then starts the wiring rehash, locating the ecu and airflow meter etc etc. I know I could use the Emerald, but I'm going to stick with the Land Rover bits as far as possible.
Anyway, won't say anymore, or there'll be no point reading the next exciting instalment.
Will there:D
Till tomorrow (or this evening, as the case may be)
Simon
Tuesday 10 February 2009
Can't think of one!
No progress on the car today - I wasn't expecting much, anyway.
Would say though, that all this activity is going on in a single car garage which is rather full up. Having the turbo engine lying around is creating problems - so this evening I knocked up a bogey (1 1/2" SHS frame, 1/2" ply sheet and some 2 1/2" wheels), so I can move the thing around.
Tomorrow, I'll get the old engine onto that, then I can move car onto driveway and give engine bay a though clean.
Next job is to get the return fuel line in and replumb the fuel lines in the boot (ie remove the pressure regulator as now surplus to requirements).
Also tomorrow, I'll try and get the auto box bits and pieces removed from the new engine so I can put on the flywheel and clutch. If I'm lucky the new flywheel bolts and spigot bush will arrive.
Need to order some stainless bends for exhaust. Aaargghhh, forgot that!
Then we should be ready for the big instal on Saturday morning. Need to be as engine crane has to go back Sat PM
Anyway, more tomorrow hopefully.
Simon
Would say though, that all this activity is going on in a single car garage which is rather full up. Having the turbo engine lying around is creating problems - so this evening I knocked up a bogey (1 1/2" SHS frame, 1/2" ply sheet and some 2 1/2" wheels), so I can move the thing around.
Tomorrow, I'll get the old engine onto that, then I can move car onto driveway and give engine bay a though clean.
Next job is to get the return fuel line in and replumb the fuel lines in the boot (ie remove the pressure regulator as now surplus to requirements).
Also tomorrow, I'll try and get the auto box bits and pieces removed from the new engine so I can put on the flywheel and clutch. If I'm lucky the new flywheel bolts and spigot bush will arrive.
Need to order some stainless bends for exhaust. Aaargghhh, forgot that!
Then we should be ready for the big instal on Saturday morning. Need to be as engine crane has to go back Sat PM
Anyway, more tomorrow hopefully.
Simon
Monday 9 February 2009
Few bits....
Just a very quick update!
Phoned Rimmer Bros today and ordered some flywheel bolts and a new spigot bush - not sure if that's actually required as I haven't taken the auto drive plate off the new engine yet, but for the sake of a couple of quid, decided it would be worth having.
It occurred to me this evening, after I'd removed the flywheel about the sense in getting a new thrust bearing and complete clutch. The old stuff seems in reasonable nick, so probably not worth the expense; or is it....
Time will tell I guess.
Also removed the take off plate for the Mocal remote filter assembly, which will also need to be transferred to the new engine, and while I'm at it, I removed the starter motor.
Tomorrow, well later today (being Tuesday already), I'm planning on removing the auto box parts from the new engine and going to finish cleaning the engine.
Anyway, that's it for tonight. More Wednesday hopefully.
Simon
Phoned Rimmer Bros today and ordered some flywheel bolts and a new spigot bush - not sure if that's actually required as I haven't taken the auto drive plate off the new engine yet, but for the sake of a couple of quid, decided it would be worth having.
It occurred to me this evening, after I'd removed the flywheel about the sense in getting a new thrust bearing and complete clutch. The old stuff seems in reasonable nick, so probably not worth the expense; or is it....
Time will tell I guess.
Also removed the take off plate for the Mocal remote filter assembly, which will also need to be transferred to the new engine, and while I'm at it, I removed the starter motor.
Tomorrow, well later today (being Tuesday already), I'm planning on removing the auto box parts from the new engine and going to finish cleaning the engine.
Anyway, that's it for tonight. More Wednesday hopefully.
Simon
Sunday 8 February 2009
Delays and ....... well, more delays
Right, last night (before I posted on here), I'd been in the garage looking at the car thinking hmmm, "Can I really be bothered?", knowing full well that if I'm to get the car back on the road, this is the only way forward.
So, knowing that last night, I made a gentle start - looking at what needed to be undone (bearing in mind that with the turbos, the engine was a bit wider than standard) and starting to undo manifolds, disconnect the ecu and remove wiring etc etc.
So, to today. The intention was to get up early, go for a swim then make a start.
In reality, I got up about 9.30, and was giving the idea of not going swimming some serious thought. Guilt eventually got the better of me, so off I went. And did about 50 lengths, without dieing, which was nice.
On the way home I popped into Paddock Wood Motorists Centre (been getting stuff from them since the early 80's!! and borrowed (alright, hired) their engine crane for the week. It's bloomin' heavy and the idea of putting it into and removing it from my car twice didn't appeal, so I got it for the week.
Then got home and wife made me go shopping with her and the boys, which ended up with us having lunch at the Nutmeg Tree in the Victoria Centre in T/Wells. Can't recommend the place enough (been having meals in there for about 8 years, and am always happy with service and food). Alas, I digress.
Eventually, got home and made a proper start, undoing offside exhaust manifold, disconnecting water feeds (more to allow easier access to other nuts and bolts), undoing oil feeds and undoing engine mountings (yes, after I'd attached the crane).
I then spent the next three hours trying to remove engine only to continuously find I needed to undo other things - and finding one bolt on belhousing I hadn't undone. Duh.
Anyway, it's out!
So now I have to clean up the engine compartment of oil, crap, dust and dirt and transfer clutch bits onto the new engine. Which reminds me, I need to get a new spigot bush and new flywheel bolts (from Rimmer Bros).
That's it for today, will post updates during the week.
Simon
Saturday 7 February 2009
Quick post - with pics. Aren't you lucky:D
This is what I collected from the nice chap near Battle
And this is the important bit - just after I'd made a start degreasing - but having run out of degreaser/got cold etc etc. Most of the crap is off though. Might have to make some exhausts. Again!
I'm now going to go and start taking Deimos apart, so you might be lucky and have more pics tonight or tomorrow.
I forgot to say, and I'm sure you'll be over the moon to hear this; I bought a bicycle and got round to riding it to work this morning. It's only three miles, but about a mile is a 1/10 hill and the mile before is a gentle uphill gradient, so, if there's no more updates this weekend, it's cos I'm too knackered to do anything. Oh yeah, and I'm gonna swim a mile or so in the morning. Finally decided to do something about my couch potato tendencies:D
Till later, tomorrow or next weekend (when the new engine will be going in!!!!!)
Simon
Thursday 5 February 2009
A New Start, perhaps
Just a quick post to let you know that I got my new engine last night. It's a 3.9l V8 from a 1994 Range Rover Classic (about 200bhp). It's done about 80,000 miles and has had the top end done.
I found it on ebay, having just flagged up about 15 Range Rovers that were potential donors, I came across an ad for, well, all the running gear (axles/box/transfer box, complete loom, ecu, pump - all I need and more).
Phoned the chap up, sounded nice enough, asked if he'd split as I only needed engine/ecu/loom and pump and he said he'd prefer not to. Anyway, I now have a load of stuff to sell - which, if I'm lucky will ensure I get the engine for not a lot. Maybe even free, which would be nice!
So, this weekend, it all kicks off. I'm going to try and remove the turbo'd engine, then swap over the flywheel and clutch assembly, move the alternator to the new engine (to the correct position), then plan on installing it the following week.
While the engine is out, I'll have a quick tidy up in the engine compartment, and get the other fuel line installed.
So, till then then, with pics hopefully.
Simon
I found it on ebay, having just flagged up about 15 Range Rovers that were potential donors, I came across an ad for, well, all the running gear (axles/box/transfer box, complete loom, ecu, pump - all I need and more).
Phoned the chap up, sounded nice enough, asked if he'd split as I only needed engine/ecu/loom and pump and he said he'd prefer not to. Anyway, I now have a load of stuff to sell - which, if I'm lucky will ensure I get the engine for not a lot. Maybe even free, which would be nice!
So, this weekend, it all kicks off. I'm going to try and remove the turbo'd engine, then swap over the flywheel and clutch assembly, move the alternator to the new engine (to the correct position), then plan on installing it the following week.
While the engine is out, I'll have a quick tidy up in the engine compartment, and get the other fuel line installed.
So, till then then, with pics hopefully.
Simon
Saturday 31 January 2009
Done it again...
Nearly another month or so has passed and.........
I'm still no nearer getting the car back on the road, well, in its current state anyway.
I've had a major change or plan which, whilst I'm still up for the turbo idea, is proving to be a complete pita, so for the moment, I'm going to get a 3.9 and chuck that it, and get the twin turbo unit on the bench (have to make one first!!!) and have a rethink - probably single turbo mounted on the passenger side (but fed by all eight cylinders - in case you were wondering!).
It just so happens that, having spent the last month or so on the lookout for a complete Range Rover or similar - which were usually several hundred miles away, and untaxed/motless, I found a pleaseant chap fairly local who's broken a complete 3.9 RR that he was going to use for a project.
Needless to say, a quick call ensued and a "BIN" on the bay took place. Not only am I to get a 3.9 with ECU, loom, fuel pump etc etc - I will also have a load of RR running gear that I'll need to sell; a) as I don't want/need it and, b) will get some money back from.
So that's put me in a slightly more positive frame of mind - looks like I'll be busy next weekend:)
Anyway, if all goes to plan, some more updated next week, with pics and smiles and happiness all round:D
Till then.
Simon
I'm still no nearer getting the car back on the road, well, in its current state anyway.
I've had a major change or plan which, whilst I'm still up for the turbo idea, is proving to be a complete pita, so for the moment, I'm going to get a 3.9 and chuck that it, and get the twin turbo unit on the bench (have to make one first!!!) and have a rethink - probably single turbo mounted on the passenger side (but fed by all eight cylinders - in case you were wondering!).
It just so happens that, having spent the last month or so on the lookout for a complete Range Rover or similar - which were usually several hundred miles away, and untaxed/motless, I found a pleaseant chap fairly local who's broken a complete 3.9 RR that he was going to use for a project.
Needless to say, a quick call ensued and a "BIN" on the bay took place. Not only am I to get a 3.9 with ECU, loom, fuel pump etc etc - I will also have a load of RR running gear that I'll need to sell; a) as I don't want/need it and, b) will get some money back from.
So that's put me in a slightly more positive frame of mind - looks like I'll be busy next weekend:)
Anyway, if all goes to plan, some more updated next week, with pics and smiles and happiness all round:D
Till then.
Simon
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