I'm still chipping away at the small jobs. Like most of NZ its been pretty wet outside recently which makes being stuck in the workshop even more cosy. I took this pic the other day. My cosy setup. Drilling and milling jobs are the warmest right now
Hence I spent a bit of time staying warm and making some of the big chunks of alloy lighter where I can. Starting with the rear plate..
Then the sump plate...
To aid the retention of the sealant I machined in some grooves between the bolt holes on both the plates. I'll be using good quality 3 bond sealant but everything helps.
So apart from drilling and tapping a drain hole (suitable plug ordered) and making some anti-windage sheet metal bits the bottom end is finished.
Oh I also lopped off the remaining unused original engine mounts - bit more weight lost
Heat management time. To keep the cam cover seals from the radiant heat off the manifolds I needed some shields. I have had a basic design in my mind for ages but keep ignoring the fact it had to be done because not the most exciting job. First off was to make some brackets to mount the shields to. A bit of 1.5mm stainless and some marking out. drilling and shaping..
A fold..
Now I had to do a second fold to form a tight Z shape. But my folder won't allow such close folds and I really want these to be neat, one piece items. So I made a teeny tiny press brake. Milled a block of steel out...
Milled a bit of plate to suit...
Welded it to another bit of plate and welded a bit of pipe atop that and pressed away. (I really am super happy I built this press !! )
Now I had the tight folded Z shaped brackets I wanted..
Tidied up..
Fitted in place...
I then cut some 0.9mm thick stainless shields to suit. I think I can go thinner. Not happy with the weight of them...
Remembered I have had a bit of titanium sheet kicking about since I was a teenager - my sisters old airforce boyfriend obtained it from from the airbase and i was going to use it to make a cycle bottle cage or something - when titanium anything on a bike was super cool. But I never used it.
Its lighter, but not by much and too small in size anyway. But now I'll just have to think of something silly I can utilise it on in this build - just for laughs/bragging rights
So I'll probably get a bit of 0.5mm SS at some point for the shields. But for now I have at least got something to deflect the heat.
They bolt to the brackets and will have some sort of heat resistant phenolic spacers to help prevent heat soak. Bolts were tigged in place..
Shield in place...
Next up was the pipework as mentioned in the last post. I cut the old one up and carefully welded its shaped end to some stainless pipe. Not super pretty but happy as the OE pipe was less than a 1mm thick so it tested my skills.
Then I started building the pipework in bits...
I got as far as there and had to stop because not enough bends to complete the path I wanted the pipes to go in - I had used two bends for the exit from the other head. More bends are on their way from China as I type.
Moving on to the next job I'd been putting off which was to make a half moon trigger/phase wheel for the cam angle sensor. I had already made a bracket to suit the Peugeot 307 hall sensor and knew the diameter I needed to start with. I rummaged about the steel racks and found a suitable piece of 3mm thick plate. Plasma cut a disc from it...
Then into the lathe where it got a big hole sawed out from its middle. Much quicker than drilling and boring...
Then bored out to final size - the process of which created a nice pretty lathe snake which came out of the lathes spindle...
I carefully marked things out, drilled some holes and mounted the plate to the cam wheel. Note my lovely warm workshop/homeless person gloves.
The bolts will be changed for countersunk items - the dome headed ones protruding just touched the reinforcing ribs within the cambelt cover..
The camcovers are well overbuilt and wont be in danger of getting hit in the back of a car like they could on a motorbike anyway so in an effort to make sure there's plenty of clearance I milled the ribs down..
I'll mill the slots out to suit on the trigger wheel and will add the remaining bolts (just in case 3 wasn't enough). It'll have half of its circumference machined down, with a corresponding amount in weight removed from the other side just to make some sort of effort to keep it fairly balanced.
I bench tested the Peugeot sensor I had picked up from the wreckers - its a dud. Probably what sent the car to the graveyard considering the prices that the local NZ suppliers want for them. A new one is on its way from overseas.
I have also ordered quite a few other little bits. New terminals for my injector plugs and a crimping tool. I'll be ordering other terminals to suit the various plugs that will be adorning the engines injection and ignition system. I want to create a loom without any unnecessary extra joints. I have never used a proper crimping tool as such. I got a set of little stainless tools for dismantling various connectors. Already used them and quite a breeze compared to my old screwdrivers, nails, pliers methods.
I need to suss out a suitable idle control valve. On the Mazda V6 engined Viva I gutted the original Mazda throttle body mounted ICV and machined up a nice little alloy housing to suit its PWM solenoid, so creating a remotely mounted ICV. I'd like to do the same but I don't have any Mazda TBs kicking about and there's also an abundance of cheaply available copies of Bosch remote ICVs available online (with good reviews) so I'll think some more about this bit.
My ignition setup is coming along - big thanks to fletcher from the oldschool forum who is posting me a Mitsubishi GTO V6 ignitor module. I'll most likely get a Jaguar v6 coilpack for the ignitor to..ignite..
So many different brands
The sticker list on the side of the completed car will be long.
'This car has been brought to you courtesy of the following' ..
Hillman cars
Honda Goldwing motor
Subaru transmission
Honda civic clutch plate
Subaru clutch disc
Honda civic alternator
Subaru starter motor
Ford Mondeo clutch release
Nissan Micra injectors
Mitsubishi ignitor
Jaguar ignition coils
KMC bmx oil pump chain
Lego Mandolorian inlet manifold plenum guardians