Sunday, 16 November 2014

continued work...

With not as much work to be done at the moment the updates haven't been as often but first of all I finished the arches and then set on sorting out a big area of the car for me, the spoiler...

It was always an area I felt had to be right to break the big slab like area of the rear up and I had found it hard to get right, I didn't want a big Fast & Furious stuck on spoiler so did a lot of research and had to trust my measurements and judgement when ordering.

So I found a wing called the F1 wing for the corvette C6. The problem was it appeared they weren't made any more or stocked anywhere. so I googled and found one for sale from corvette forum in 2013...it appeared not very popular in america as  spoilers go and the guy hadn't sold it. so i messaged him...and again...and again....and after enough pestering we got chatting and a sale was done. I want to thank him a lot and show that you can trust a random stranger over the internet.

It arrived and I was unsure whether to chop the ends off or leave them (you'll see below. I've decided on leaving them and I think the finish will be really good. opinions welcome on it or ideas if you think it could be improved.

On to the bodyshop!!...





Sunday, 2 November 2014

Oil Leak, mud guards, mirrors

Following on from the shakedown tests I decided to look into the oil leak more and prepare for what I thought was going to be a headgasket issue. So  started the strip down of the engine.


Im getting extremely quick at getting the intake system off now! However the rocker cover and cam cover needed to come off as well as the shield. This is made hard by the engine cover stay, shown in the pic above. I think following completion of the car ill make a change in this area to make working on the car easier.

So a little tip, because I needed to remove the cams and belt tensioner I wanted to help myself with setup and not have to do the timing again. So I moved the crank to TDC (Top Dead Centre) and cable tied the belt to both cam pulleys.


this made putting all back together easier...anyway So i whipped it all off and found a weeping camseal. Enough to potentially cause the oil leak as this area of the engine isnt high pressure but none the less during running would leak and so would match my oil leak as it would run down the head to the gasket and then run along that and behind the alternator bracket, so I removed the weeping seal first....


As you can see it came away well! So it had gone past its best, so I replaced them both, these were probably the only two seals I didn't replace when rebuilding the head of the engine...why...I don't know! So I put it all back together and will see how I get on but hopefully it will be fine now and much better then doing a headgasket! Getting the timing right was easy and it all went together easily.

Next was some replacement mirrors the new ones were not just too small and dangerous but also the glass brought objects closed like a zoom so had a smaller view. Some slightly bigger mirrors and a glass (convex) to open up the view and it feels much better. to put it in perspective. I could hold the two mirrors next to each other and in one see my nose and eyes, the others could see my whole head neck and around it.




Next was to work on the mudguards and I was able to do the drivers side fully.


Passanger side will need to wait as the filter is in the way partly so I've brought a 70mm 45 degree hose to move it out of the way, I will just cut a hole in the  mud guard for it to pass through if required. This will also bring it closer to the cold air feed hole in the bodywork so benefit all around.

Tuesday, 28 October 2014

Took the car out for a shakedown

So at the weekend I took the car out for a shakedown! the first shakedown on the saturday had a lot of smoke billowing out off parts near the exhaust, I expected this to some degree from wd40 and oil burning off. However it took a long time! Mainly because when the oil filter came off, oil went everywhere...it was slightly embarrassing!

However on the Sunday it was all burnt off and the car was run normally with no major issues.



I have a small oil leak which looked to be from the headgasket...however after stripping the engine back a bit last night it was the camshaft seals which appear to be leaking. So ill be picking up some gaskets for that and refitting and doing the timing again. Should have the engine back together tonight and oil leak fixed.

the seal had seen better days! And teaches me a lesson...replace all seals!!!




Seeing as the geometry isn't set the car did well, grips well with the wide tyres and once moving the steering feels nice and solid and not too heavy. I will want to replace the springs for softer springs as the ride is a bit too harsh for UK roads in my view. I will also probably at some point in the future replace the rear coilovers for ones where the dampening is on the top as that's restricting my lowering height at the rear.

The car boosted to 7psi without any issues and now I know the oil leak isn't head gasket the 16psi shouldn't be a problem going forward. I'll complete the boost controller solenoid fitting after the bodywork is done and once I've run at 7psi for a little amount of time..

Next stage is to replace the mirrors, the may look small and good, but were useless! So I have found some ones which are bigger but don't look too bad.

As well as this I will create some arch liners to try and keep the mess off the rest of the car! I can only clean it so many times before I get bored. After these two pieces are done it will be time for the bodyshop.

Thursday, 23 October 2014

Got my reg plate and first drive

So my reg documents arrived, on the day it arrived it was my sisters wedding, so I'd been drinking...so had to wait a day!

Put on the reg plate and headed somewhere local... My mums! The turbo / exhaust manifold was smoking a lot when I arrived but it hadn't had a proper run since fitting with oily hands and WD40 everywhere.

By the journey back, smoke wasn't as bad but it is only 6miles so don't know how long that takes to burn off so I'll keep an eye on it.

Being so low the car feels fast and very rock solid, the car was boosting fine, although being late and wet I only boosted to 4.5psi...so plenty to go! 10psi with current setup, once boost controller connected will be 14psi.

It then rained and showed up I will want some rubber to go on the top door hinge fitting to keep water out, so that will be easy enough.

Overall a good test run and I'll use this weekend to get some more test miles under the belt and ensure no niggles exist before going into the bodyshop!

Sunday, 19 October 2014

steering wheel, screen, indicators & further prep

So im still waiting on the DVLA for the reg number. Over 3 weeks now, bit of a joke really!! For an organisation which looks after all UK vehicle matters id expect a better turn around.

So I fitted the new oil cooler, drained all the new oil :( and got it running and the car is running very smooth so that is some good news...although of course there has been no engine load on it yet.

So first of all  i ditched the Toyota wheel as its 380mm diameter which is just massive. Now as I have no power steering I don't want to do to small, so went down to just 350mm for now and its made a big difference when sat in front of it already, I may be able to go down to 320mm but definitely not 280mm unless I work on my arms at the gym all the time! as well as this I fitted the rear view camera and also the screen. All worked fine. Obviously at the moment the interior is just to be practical with ideas for later on and this has opened up my eyes to needing a larger and better screen when doing the interior.


and rear camera position....


Some will of spotted the boost controller, that has been wired in and plumbed in as well, although I haven't done the solenoid at this point as I just want to make sure the car is working as expected before trying to raise the performance.

Next was the indicators as i wanted to get rid of the bobbles on the front so I got some LED waterproof strip. (600 leds a reel) and cut them to about 10cm in length and fitted them to the headlight covers. Much nicer and cleaner and can be seen clearly. these are actually brighter and better then the first set I had on for IVA which I failed with.


Following this I lowered the front end of the car to roughly the ride height I wanted. It has a ground clearance of about 3 1/2 inches. I suspect this is too low so I may need to raise it half an inch or so but ill work that out.

I also fitted some much smaller and nicer wing mirrors, now these I believe are too small, but being from a motorbike which generally have a universal fitting (not all) means I can find some bigger ones that will suit.


Im still to decide on what wing for the rear, it needs a wing to break it up but I don't want OTT. Hopefully the reg number will come this week, as im running out of time for test drives with roads being half dry at least! Today would of been perfect....typical!

Tuesday, 7 October 2014

Turbo bracket, Rear view camera and broken Oil cooler

So I got the oil cooler off...well it had had destroyed itself! Luckily I found all the chunks of the metal and fitted them together so I know no large pices of metal are in the engine so thats good.

Either way I will still be changing out the brand new oil for some more brand new oil after its warmed a bit so i know it removes as much as possible.


Following this I modified the turbo stay for the CT20b from a Celica. this now has a slit to it rather than a hole so it can be mounted on properly with the support.


Next I tested the rear view camera on a spare battery I had. Its a wireless from front to rear so i dont need to run any cables down the car. I bought the parts seperately as I wasnt sure how well it would work etc... and the cost came out at less then £30. Now its not amazing but will definitly provide a big improvement on rear visibility. Going forward long term I will get a larger screen for when I do the interior properly as currently its a 4.3" and i think a 5" would be better.

the two shots below are a daytime colour, which is a bit washed out as its from in the garage and night vision one.


Now I just need to decide on where to mount it at the rear.

As well as this the boost controller I have, I will start plumbing in the pipework along the car, although not connecting it as I want to test run the car with the boost just off the actuator at first to make sure everything is ok. That will only give me about 0.5bar of boost I believe but thats fine for test runs to ensure everything is ok.

Monday, 29 September 2014

Next work parts and problems

So following the IVA pass it was on to the DVLA paperwork first of all. Well that was confusing, thank god a guy at work had recently done it! Made life a million times easier (I hope) So i sent off all that was required;

V55/5 - car registration form
V627/1 - build form
2 forms of ID
Donor car V5C
Photos of build
1st Registration cheque
1st yrs tax cheque

I'm hoping to get an age related plate because of the parts used from the Donor car.

Following this, this weekend I decided to work on fitting the larger turbo. The mr2 engine (3s-gte) had many revisions over the years. Mine was a rev2 , one of the things that wasnt quite as good with this revision as later ones is the turbo. It would not hold the boost till redline and would start to tail off at about 5500rpm. Upgrading to what is known as a ct20b which came on later revisions of the engine resolves this problem holding boost till the redline.



a long time ago, I fitted a metal head gasket and that was exactly for this reason, it will allow me to raise the boost up to 15 / 16psi long term. this will levae me with

new fuel pump
aftermarket side mount intercooler
one set colder plugs
ct20b turbo
boost controller
Metal headgasket
raised boost to about 15/16psi

This will give me about 290/300bhp.

Following a small run of the engine with the new turbo in (to help get rid of any contaments that may of got in there. It was time for an oil and filter change.

The oil came out and wasnt super clean seeing as id only done 15miles, but the engine had probably been run for about 7hours if not more in total so fair amount of actual running not under load but on an engine that hadnt run for over a year previously.

So I fill up the oil and new filter and start it up, all running fine. I give it a small rev to confirm no leaks and the oil filter shoots off at me! Oil everywhere, luckily being on the drive the engine is off within 3 seconds. I thought that was weird as I knew id put it on ok, when I looked the actual oil cooler mounting bracket which the relief valve tightens into had broken. It must of been over torqued in the past. The photo shows the broken metal it should be just a smooth thread all the way round, the thread you can see is a loose chunk.


I've now removed the oil cooler and bracket (luckily its a simple job on the kit car with no rear firewall.) Took me 10mins max and at least I know the two hoses (known as hose from hell and the hose from hell on earth) are both simple for me to change.

When piecing the puzzle bits back together it went together and a small chunk of metal was missing from the top. I can only presume this fired outwards based on the spraying of oil when it did go. There would be no way it was ingested into the engine.

So I now have a very oily drive and a dirty engine again which will need cleaning a lot. but when I get the replacement part it should at least be a small job. I can fit it run the brand new oil that's in it an idle to warm it up....then empty it again and put a fresh batch in.

The reason for warming is it will be thinner and I should be able to get more of it out and any small metal bits will flow with it (if there are any).