Tuesday, 12 August 2014

Outer bodywork, Emissions and Noise, IVA prep and little jobs

So first of all I continued with the outer bodywork, making sure the exhaust fitted the rear hole but the bodywork was close enough to not require another test in terms of radius, I then refitted the fog light so it was vertical.

At this point I then retested the rear lights and one indicator didn't work...Took a few hours but I traced it back to a connector which was a bit loose within the car so tightened it all back up.

I also fitted the rear reflectors to meet the test requirements. They have been fitted high up to pass a requirement that they are always visible even when a door (in this case rear section) is open. I will use a stay to hold it open at a height which means the reflector and lights are still visible from the rear.

With the number plate light already fitted and the catches flush this means this area of the car should pass the IVA without any difficulties.

Next I did some more work on the wiper, although complete the motor mechanism was so strong in its movement it was actually moving / twisting the bracket made originally. This may be down to it being too thin, however I actually think a further brace would of been needed anyway to remove all movement. So I may a brace that covered both axis of movement, when testing this the good news was all movement was gone and the wiper motor was now stable.

With the exhaust now fully fitted including being welded it was time for two important tests. Emissions and Noise test. So I fired the car up got it warm and performed the noise test;

At Idle;

at 4000 RPM; (the manual states 2/3rd's of max power and max power on this engine is at 6000rpm

Although I expect its a bit louder then that more around 93Db, however that is with 2 backboxes and a Db Killer in the exhaust so the noise shouldn't be an issue.

Next was emissions, being an EFI engine I had strong hopes of being ok and being a 92 engine doesn't require a cat test. Which does mean a letter is required to prove engine age (don't use an im port engine like me, been a nightmare to get proof from Japan!)

So I bought a gunsons gastester off ebay and did the test....good news well under the required emissions so that shouldnt be an issue either.

Next was the wing mirrors, now these were never going to be pretty looking through cars that people have built that are similar or even the Ultima to some degree I knew they'd need to be out wide and up high...so I tried to get an idea of where.

Once I knew roughly where they'd need to go the mounting was put in....

Not pretty but they should do the job and give the visibility required. with the mirrors done on the test fit and the final settings to be done closer to the time. The outside of the car is finished (for now at least)

So I moved on to the interior, with a few jobs left to do inside before being ready for the test. The first rule is the radius of edges, Im taking no risks, anything they want to touch with that sphere is being covered.

However the amount of jobs now is beginning to drop and leaves me with only interior jobs and an extension of one area of wiring near the engine. I'm feeling pretty good about whats left and the possible time frame I have to do it. Hopefully the weather will be in my favour for the next couple of weeks.

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