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Nice, welcome back man. I know very well what you mean ab out houses, worth it when they are done - gives you a nice place to retire to.
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J.P
Posted a lot
I like to eat ice cream and I really enjoy a nice pair of slacks.
Posts: 1,175
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Awesome! Glad to see this back. All the best with the final hurdles!
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Apr 20, 2009 19:36:48 GMT
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Hi guys, First a note, If there are a number of A's missing from this post, it is because the A on the key board is on holiday The imp project has been ticking along quietly, I have been planning and ordering parts that are required. This weekend I popped back to my folks place, tidied up dads garage and picked up the last remaining parts for the build. I then got home and ripped everything out of my work shop nd re-organised it! I have three benches now, ready for work to begin. I have decided to start with one of the more daunting tasks, the plenum. Some of you may remember that on the first drive the imp came on boost and immediatly split the plenum in half! A design fault on my part was the cause, so I had a think and decided that the join was wrk and of too small an area. To fix this I had to recess the inlet pipe and re-glass it in, to chop the carbon I got out the trusty dremel and diamond cutting wheel. Mask donned I marked it up and got hacking! The result is a join of about 50% more area, easier to get the glass fiber around the joint (I used glass for this part as it is much more flexible than brittle carbon). I temporarily held the two parts together with racing tape, this also handily sealed any small gaps where resin would leak on to the outside surface I cleaned up and then got the glass and resin out, gloves on and sticky fingers all round, all I have to worry about now is my other half complaining about the smell! By this time it was getting dark (no strip lights sorted yet!) so I packed up and washed the dishes as recompense for the resin odours ;D I will show you the result tomorrow Lots of love J
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edcobb
Part of things
Yellow=Faster
Posts: 167
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Apr 20, 2009 21:25:32 GMT
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Looking good mate! look forward to seeing it again
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1980, 20valve Mk2 escort 1986, Mk1 Mr2
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Davenger
Club Retro Rides Member
It's only metal
Posts: 7,272
Club RR Member Number: 140
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Apr 21, 2009 18:51:57 GMT
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Good to see you back on it dude!
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bazzateer
Posted a lot
Imping along sans Vogue
Posts: 3,653
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Apr 30, 2009 21:36:20 GMT
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Where's the pics then?
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1968 Singer Chamois Sport 1972 Sunbeam Imp Sport 1976 Datsun 260Z 2+2 1998 Peugeot Boxer Pilote motorhome 2003 Rover 75 1.8 Club SE (daily) 2006 MG ZT 190+ (another daily) 2007 BMW 530d Touring M Sport (tow car)
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May 27, 2009 21:09:41 GMT
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Right, finally time for another update! I've been struggling with the age old problem of flaccid mojo! finally found something that has stoked my fire and tonight i've got back on it! After the last instalment, I was still not happy with the way the plenum was working, I was not too sure what to do until I saw the thread on the turbo clan (posted in the general board). From this I remembered looking at lost foam moulding to make complex shapes without a multi-piece mould and careful draft to ensure smooth extraction. Bouyed by the clear path ahead and positive vibes from the clan plenum, I bought some foam! This is the stuff I bought - It is solid roof insulation styrofoam boards, perfect! Sections were cut with a wood saw in roughly the right size and stuck together with nomorenails, this foam block was then stuck to a chipboard base. From here I decided to look at what was to be fitted into the plenum, making sure that it will all fit now, will most certinly avoid massive ball aches in the future! Here are the trumpets - Here is the old plenum, it is still useful as I know that it fits in the incredibly tight space that is the imp engine bay! Next I started to hack up the block of foam into the basic shape I had in my mind, all this was done using the wood saw - Once this was done I took to it with a sanding block, this gets so messy it's untrue, however it is worth it, the foam is so easy to work and get into that shape you have in your head! I decided to strt with the inlet pipe and work down from there, the plenum was basically shaped and the two parts then mated together - Once I was happy with the general shape, the inlet was joined using no more nails, and a thin skim of filler used to shape in the corners - It is all currently hardening up ready to be shaped again tomorrow, and the lower edge curved in, then it's final shaping, cleaning, and covering with brown packing tape ;D ;D More tomorrow xxx J
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Last Edit: May 27, 2009 21:10:56 GMT by Blown_Imp
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PhoenixCapri
West Midlands
Posts: 2,685
Club RR Member Number: 91
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Fantastic to see you've got your mojo back, always a pain when it goes walk about!
Looking forward to seening the outcome of the plenum as I've been thinking about doing a similar thing myself.
Keep up with the excellent write up and How To's ;D
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sparko
Posted a lot
Posts: 1,627
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May 28, 2009 10:10:21 GMT
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dude thats a quality idea! keep it up!
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DutyFreeSaviour
Europe
Back For More heartbreak and disappointment.....
Posts: 2,944
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May 28, 2009 14:59:41 GMT
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Been missing the step by steps on this thread - it really helps avoid those 'how the heck' moments on my own build....... Appreciate it James. Good to see it back on track.
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Back from the dead..... kind of
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May 28, 2009 21:14:50 GMT
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Evening chaps, It would appear that I did not do a lot tonight, however it was careful measured progress, go in hammer and tongs with this foam and it's usually time to start again The filler had gone good and hard, ready for sanding and shaping, I was being ultra careful as the foam is removed far faster than the filler, so any erronious contact would result in dips where there should be flats/lumps! To get into the tight spaces and make the filler into smooth radii, I quickly shaped a bit of scrap foam to make a sanding block - This helped enormously, making light work of the filler and keeping the abrasive away from the foam Progress was swift in places and hard going in others, mainly due to access and controlling the sand paper. Some progress shots - Once yesterdays filler was smoothed, I whacked on the filler for the lower radius that will transition into the flange, suprisingly in the heat and humidity of this afternoon, it went off in minutes! This was duly smoothed and fettled into shape, and the finished article ready for the tape and composites is so - I'm dead pleased so far! As I currently don't posess any parcel tape the next stage will have to wait until tomorrow, then it gets exciting!!! I also managed to get some paint onto my coolant system swirl pot, more coats tomorrow with photos I promise Thanks guys J
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Last Edit: May 28, 2009 21:17:10 GMT by Blown_Imp
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May 28, 2009 21:21:35 GMT
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Looking good - Interesting to see people take on things like this!
One thing though - with lost foam don't you tip a solvent inside which dissolves the foam.... Will this dissolve the filler too, or are you going to manually chip it off?
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May 28, 2009 21:31:24 GMT
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This is where the tape comes in, brown parcel tape is one of the best release agents know to man So when it is all sorted carbon wise, I can melt most of the foam out and then just peel the tape off, pulling the filler with it This is the plan, what actually happens could be a long way from it! Cheers J
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May 28, 2009 21:34:35 GMT
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Good thinking. I admire you for having a go if it turns out well or not - Sounds like something I'd do!
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DutyFreeSaviour
Europe
Back For More heartbreak and disappointment.....
Posts: 2,944
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May 29, 2009 10:35:25 GMT
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If I ever possess the patience, I'd love to have a go at something like this..... it'll be a lot easier having seen this documented too. Thanks James. Good luck with the tape and next stage.
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Back from the dead..... kind of
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May 29, 2009 14:50:20 GMT
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Good afternoon all, Today has been split into two halves, morning - clean and tidy house, afternoon - car. I probably wont get much more done this weekend I would have thought as this is the last weekend I get to see my girlfriend for the next 9 months So this afternoon I thought I would have a crack at the fuel swirl pot, the fuel system that got the car running previously was simply the stock fuel tank with a high pressure pump and a return to tank. This is not the most reliable system, as it can suffer surge and the pump can pick up air bubbles, it also means that there are high pressure fuel lines running the length of the car and I think this is a little dangerous! So to stop this happeneing I have got a low pressure electric pump, the type used for carbs, this will feed a swirl pot at the rear of the car, that will in turn feed the high pressure pump. The high pressure pump will return to the swirl pot, and there will be a return pipe from the swirl pot to the fuel tank. So the swirl pot needs four connections - 1.low pressure in 2.low pressure return to tank 3.high pressure pump feed 4.high pressure return I had some 3" stainless pipe, with this I calculated the volume and duration to empty under full load, with a 300cc capacity it would last around 30 seconds. So the pipe was cut using the trusty angle grinder! - The caps were to be made from stainless sheet, I marked out the circles and cut them to a vague kind of circle using a hacksaw, mainly because the disc on the grinder has worn out and i've lost the new ones The belt sander was used for final shaping, awsome bit of kit, don't know how I lived without it Perfect! Next up are the connections, the rest of the car uses 1/8th NPT nickel plated brass, nice and neat, I had some stainless tube that is perfect for tapping out to 1/8th NPT, so sections of this were cut and filed smooth - The section of 3" pipe was squared off at the ends, then the 12mm holes drilled for the fittings - Now I havent used my welder for a loooong time, so the welds started out a little shoddy, but by the end of the welding they were not too bad, the first bits - The caps were drilled and fitted up - Then welded - Ill probably give it a polish to get rid of the welding marks, all good. So I will get back to it after the weekend guys, hope everyone hs a good one J
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Last Edit: May 29, 2009 14:55:41 GMT by Blown_Imp
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Davenger
Club Retro Rides Member
It's only metal
Posts: 7,272
Club RR Member Number: 140
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May 29, 2009 14:52:47 GMT
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Legendary skillzzzzzzzzz as usual
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good work dude! Mojo back - ready to win! have a great weekend with Mich (send our love to her!) and then i'll look forward to seeing how this progresses over the next few weeks. i'll probably be speaking to you shortly - genius plan being hatched!
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Good evening guys, I have been busy! The weekend was ace, has a lovely time with Michelle just relaxing before she goes. Now I am trying to keep busy, making sure my mind is elsewhere and not worrying about her, and this means cars! Today to keep mixing it up, I decided to do a little bit to the fuel and cooling systems. First up was the low pressure pump for the fuel system, this is to be mounted as close and as low down as possible to the fuel tank. The front inner wing was perfect. I borrowed a riv-nut gun from a good friend, this tool makes bolting bits on a joy! I started out with this pump - It's a posiflow facet, good for 200bhp according to the manufacturers, not that i'll be anywhere near that figure! Lucky for me the pump was tapped to 1/8th BSP already, so no fiddling around with taps trying to put my nickel brass fittings in Location sighted - The holes were drilled, the bare metal primed and given a splash of black from behind then the riv-nuts riv-nutted - I shortened the long fuel line that ran to the old high pressure pump and fitted it to the new low pressure item, then it was all bolted in using stainless M6's - I then decided to scope out the back end, things are real tight round here, very little room left to play, so I decided to tidy up the lines and electrics a little. I think this is how it is all going to fit in here, with the EDIS module (not shown) next to the relay board - The fuel swirl pot and pump both need mounts fabricating, the flow goes from the low pressure pump into one of the side fittings, fuel is then drawn out a 90 degree fitting on the bottom of the swirl pot into the fuel pump (on the far side). The now high pressure fuel will come out of the pump towards you and into the fuel rail, the injectors sup as much as they need and what is left goes into the regulator, what is left after the regulator has maintained pressure returns to the swirl pot through the other side fitting. The low pressure pump should always be able to flow more than the high pressure pump, once the swirl pot is full the excess fuel will flow out of the top of the swirl-pot and back to the tank. Convoluted! After that brain mashing I decided to look at the cooling system again, the header tank is painted and ready for installation, I mocked up the position here - Riv-nuts were again used to great effect, the only issue I can see is that the water pump is going to have to sit at a funny angle to be able to prevent the joining pipe from kinking ( ) Looks quite neat! The good thing about this set up compared to last time, is the fact that the water pump now has a head of water supplying it, so it should self prime, it sure didn't last time! Right, i'm off now, more tomorrow evening Cheers J
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Last Edit: Jun 1, 2009 20:53:39 GMT by Blown_Imp
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edcobb
Part of things
Yellow=Faster
Posts: 167
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Looking awesome dude
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1980, 20valve Mk2 escort 1986, Mk1 Mr2
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