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it feels like not much has happened recently hence the lack of updates. But work to fit the fuel pipe plumbing, high & low pressure pumps, swirl pot and the associated wiring and relays is almost done. The pumps are bolted in and 90% of the fuel lines are plumbed in (just waiting for 2 10mm to 8mm hose reducers to arrive) and both both pumps are wired via 2 relays which are in turn controlled by a main fuel injection relay. I've managed to identify the constant and switched live feeds which are wired in along with a 6way fuse box. on the same board i've also mounted the edis stuff so all that remains is to refit the engine loom and wire the 7 wires to the car. ![](http://i204.photobucket.com/albums/bb291/maph2/covin/DSC_0604_zpsbbrvzlyy.jpg)
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Mark
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Posts: 3,821
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Another step closer. ![:)](//storage.proboards.com/forum/images/smiley/smiley.png)
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BMW 320d (fridge on wheels)
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the engine bay wiring on the "car side" is finished, so can now focus on refitting the engine loom and wiring that to the car. the engine loom has 7 wires but it only really needs about 4 of them connected to fire up the engine. just waiting on one 10-6mm hose reducer then all the fuel line plumbing is completed. To break the boredom of the wiring, and whilst the wheel was off, i replaced the axle boot which had split ![](http://i204.photobucket.com/albums/bb291/maph2/covin/DSC_0608_zpsxhp6oxqv.jpg) and as I'd just bought a new longnose fibreglass bonnet from a local porsche specialist, they helpfully loaned me some early 70's rear arches that had been cut off a scrap shell, so i could take a mould. ![](http://i204.photobucket.com/albums/bb291/maph2/covin/DSC_0609_zpsvowmad1m.jpg) the paint work was polished up and coated with car wax and left "unbuffed" ![](http://i204.photobucket.com/albums/bb291/maph2/covin/DSC_0610_zpsdqdlcl5s.jpg) rather than make a female mould to cast a new "male" mould, i've fudged it and laid up a thin layer of fibre tissue which i'll fix in place on the car as the outer skin then glass up from the rear to get the strength. its much quicker and cheaper as its uses far less material but the downside is i'll need to do a bit more surface prep to the new arch....but i'll have to do a lot of glassing, filling and smoothing anyway to blend in this new arch
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The last of the fuel line connectors arrived yesterday so got a can of unleaded on the way home. i gave the lines one last visual, chucked the petrol in the tank and got the pumps whirring. It took a while for the low pressure pump to suck the fuel up but after 5mins of bubbling, burping and gurgling the pumps started to make a low hum. then i heard the hiss of high pressure fuel spraying out.....all my handy work was fine but it appears the fuel regulator had been dismantled previously - for a new diaphragm perhaps.....the 4 bolts holding the top on needed tightening up then all was good. the regulator appears to be adjustable but not sure if that's standard for a xr2i ![](http://i204.photobucket.com/albums/bb291/maph2/covin/DSC_0617_zps05feuyxm.jpg) Cranking the engine over got no results, so checked for a spark but noticed the plugs were dry (have ordered some new plugs BTW). i did shoot some bradex into the throttle body which produced a 1 foot flame nearly taking off my eyebrows, confirming a good spark! ![](http://i204.photobucket.com/albums/bb291/maph2/covin/DSC_0618_zpsiqngsmoq.jpg) The injectors aren't firing which i think is a "switched live" wiring loom issue. i rigged up a temporary starter button in the engine bay and tried connecting some of the engine loom wires to permanent live feeds which i "think" worked......the engine did cough but by that point the battery was flat. The problem lies with me misinterpreting some loom diagrams to get the engine loom wired into the relays (i have got at least 2 different wiring instructions off the internet). Hopefully my garage session tonight should get it sorted.
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Mark
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Liking the progress on this. I hate bloody wiring! I've had to have someone else do mine. ![](http://i210.photobucket.com/albums/bb187/markbrown100/E21%20New%20Build/IMG_2689_zpsdaf241eb.jpg) Look forward to seeing the Covin run soon. ![:)](//storage.proboards.com/forum/images/smiley/smiley.png)
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BMW 320d (fridge on wheels)
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Still not firing up :-( there is definitely a spark which means there is a signal from the crank sensor. No crank signal wouldn't get the EDIS to spark. need to check signals from the edis to the ecu - PIP signal to the ecu and the SAW signal from the ecu. then check injector pulses from the ecu to the injectors. i've ordered a noid light to check signals. In other news, here's the passenger rear arch casting ![](http://i204.photobucket.com/albums/bb291/maph2/covin/DSC_0619_zpszofumh3o.jpg)
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Feb 14, 2014 15:44:14 GMT
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Whilst the covin is really pi$$ing me off by not firing up, i've sold the 8x15 fuchs for hard cash at lunchtime and immediately orderd a pair of new 5.5x15 SSP fooks fuch replicas from vwheritage, with free delivery and 14% off as its valentines day.....back of the net!
i think i'm gonna do a bit more investigation of th wiring whilst i wait for another ecu to arrive. if it won't fire with another ecu, i'll be considering the bike carbs route using a second chopped up inlet manifold.
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its still not firing although its making an occasional weak "cough". It has spark and the injectors are pulsing. the injectors were gummed but putting 12V across them from the battery has freed them up. i need to investigate if i have low fuel pressure as it looks like the FPR isn't a standard one. whilst the injectors are pulsing, little fuel seems to be in the chambers as the plugs are not getting wet.
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goldnrust
West Midlands
Minimalist
Posts: 1,872
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Feb 19, 2014 10:04:08 GMT
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I've been quietly following this for a while, it's a really interesting build. I think you made the right call going for the narrow rear set-up ![:)](//storage.proboards.com/forum/images/smiley/smiley.png) Regarding the engine not starting, if you've had to work to free off the solenoids inside the injectors then I'd put good money on the rest of the insides of the injectors being rusted/dirty. You could send them away a ultra sonic cleaning and flow testing, which may rescue them but at approx £50 last time I had it done it might be cheaper to find a good used set on injectors. I had a set of Rx7 injectors that looked fine and the solenoids operated fine but I sent them away for cleaning before fitting them anyway. They were rated at 440cc/min when new, on the initial report 2 flowed around 400cc/min, 1 flowed 140cc/min and one didn't flow anything. After cleaning 3 flowed 430-440cc/min but the one that was filled clogged would only flow 200cc/min still, so I had to buy some more anyway...
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Feb 19, 2014 14:22:28 GMT
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thats really useful. i think my next session, i'll get the fuel rail off and do the jamjar test to check the injector spray. Injectors 1 and 4 clicked with 12V across them but injectors 2 and 4 definitely took a few attempts to hear the clicking.
perhaps get one of those cheap ultrasonic cleaners...worth a shot
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Feb 22, 2014 14:11:58 GMT
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![](http://i204.photobucket.com/albums/bb291/maph2/Gene-Wilder-Its-Alive_zps3cef1299.jpg) Running.................last night....briefly for 3mins before I shut it down as there was no cooling system plumbed in. I stripped out the injectors and forced through some carb cleaner. back on the rail I did a test fire which shot fuel all over the place so I bolted the inlet back together and it fired up rather quickly. ![](http://i204.photobucket.com/albums/bb291/maph2/covin/DSC_0631_zps4dwl9kfy.jpg) to celebrate, this morning I got tyres fitted to the new 5.5x15 fuch rims I bought last week......185/65r15's ![](http://i204.photobucket.com/albums/bb291/maph2/covin/DSC_0632_zpsjmpxsat4.jpg) with a spare 30mins this afternoon I fitted up the wheels then did this..... ![](http://i204.photobucket.com/albums/bb291/maph2/covin/DSC_0633_zpsmqomjrza.jpg) ![](http://i204.photobucket.com/albums/bb291/maph2/covin/DSC_0634_zpsdc0tsdnn.jpg) ![](http://i204.photobucket.com/albums/bb291/maph2/covin/DSC_0636_zpsdwebnbvd.jpg) Was very therapeutic......
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Feb 22, 2014 16:38:53 GMT
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I think you're doing the right thing taking off the wide body stuff. It'll probably drive a lot better with reasonable sized wheels too. Just one thing: See that flexy exhaust bend? it'll last about ten minutes like that - they are designed to be kept 100% straight and just take up a few degrees play in the engine mounts/exhaust rubbers. Bent at anything more than a few degrees will see them split in no time at all.
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Feb 22, 2014 17:47:48 GMT
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not ideal is it.....kinda sums up the level of workmanship of the PO. fitting the early style rear bumper will probably mean moving the exhaust hangers so the whole exhaust system will get rejigged.
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Mark
Posted a lot
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Feb 22, 2014 19:20:21 GMT
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Good work! ![:)](//storage.proboards.com/forum/images/smiley/smiley.png) +1 on going with narrow body. It'll look much more in keeping.
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BMW 320d (fridge on wheels)
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Anglia68
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Feb 22, 2014 20:38:19 GMT
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Nice work on the Covin and I am fascinated by your fibreglass work and will be following your progress on the rear wing casting with interest as it could prove to be a new and useful technique for a project I've had on the back burner for quite a while due to my very limited grp experience.
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Feb 23, 2014 14:45:16 GMT
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here is the arch skin offered up to the car fixed into position using the rear light corner as a reference (I made a cardboard template from a real '72 911) ![](http://i204.photobucket.com/albums/bb291/maph2/covin/DSC_0638_zpsxzekt4fp.jpg) However, the wheel isn't quite centred in the arch so I reckon i'll need the move the complete arch about 1 inch back so that it all looks visually right.
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Feb 28, 2014 12:57:13 GMT
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One of my dream cars is an early narrow body 911 and seen as I know I'll never be able to afford one , one day I'll be buying one of these!
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Feb 28, 2014 13:07:08 GMT
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keep an eye on ebay - they regularly crop up as failed projects or cars that have been off the road for years. If you want an early 911 without the cost, this is the cheapest way but you need to be prepared for some fibreglass action!
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The passenger rear arch is 99% done, bar final surface prep and blending in ![](http://i204.photobucket.com/albums/bb291/maph2/covin/DSC_0656_zpszikogasm.jpg)
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Mark
Posted a lot
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Posts: 3,821
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Good work. ![:)](//storage.proboards.com/forum/images/smiley/smiley.png)
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BMW 320d (fridge on wheels)
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