Stuart_B
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| posted on 3/2/10 at 07:01 PM |
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i so which i could carry on with my install, as i was going to use a eaton supercharging in a few years time.
nice work david, i will love to this a some shows, and meet you would be good as well.
stuart
black mk indy, 1.6pinto on cbr600 bike carb's.
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flak monkey
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| posted on 3/2/10 at 10:41 PM |
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Should be at Stoneleigh, if all goes to plan....and it doesnt go bang on the way! 
Sera
http://www.motosera.com
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goaty
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| posted on 4/2/10 at 07:47 AM |
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optimistic
I am the same with mine, hoping the fist time it turns over all gos well.
Another one for you.....Do you knwo what starter will work with my flywheel set up?
would a duratec ka one work?
cheers dave
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flak monkey
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| posted on 4/2/10 at 07:51 AM |
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What do you have again? I cant remember.
There are essentially 2 different starters, the mondeo one and the St150 one.
The St150 sits closer to the block as the flywheel is slightly smaller than the mondeo one.
I *think* all the aftermarket steel flywheels use the mondeo one.
The Ka engine is totally different.
David
Sera
http://www.motosera.com
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goaty
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| posted on 4/2/10 at 07:55 AM |
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titan flywheel so i need to find a mondeo one, or some smaller equivilant if there is one.
cheers david
ps, charger bracket is made so i can now look at mounting into the chassis to work out the alternator mounting....should be fun...lol
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goaty
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| posted on 4/2/10 at 10:54 AM |
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any news on your rad and coooler yet? mine wont be ready for another month yet lol
cant wait to see what they will come out like
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matt.c
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| posted on 4/2/10 at 08:03 PM |
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Do i need to get my helmet and gloves out yet? 
Is it finished yet? 
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flak monkey
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| posted on 5/2/10 at 09:40 PM |
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The rad is done, intercooler will be sorted early next week hopefully.
Was hoping the prop would be ready this week so I could finally fit the engine, but sadly its not finished yet.
Looks like it will be next weekend for the final fitment now 
David
Sera
http://www.motosera.com
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flak monkey
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| posted on 7/2/10 at 03:30 PM |
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Very little progress this week. Crap week at work hasnt really put me in the best frame of mind for working on the car.
Did get a few little jobs done however...
Beefed up the steering column support, painted and fitted the column properly too. Seems much better now
 
Steering column support
 
Column finished
Fitted the oil filter housing from Raceline, was expecting it until next week, but there we go Fingers crossed the filter will clear the
chassis.
 
Oil filter housing
Bolted down the battery on the top of the footwell. Amazingly small compared to the old one, and will allow me to mount the header tank above it and
still clear the bonnet. This will leave me more room to fit the swirl pot and oil tank for the rotrex up on the footwells too.
 
Battery and tanks
GRS also sent over some pics of the radiator which is nearly finished, just need to fit the bleed connection on the top of the right hand tank. Its
basically the same frontal area as a polo radiator, but is a twin tube core and the pipes are designed to clear the chassis better. They will be
making the intercooler this week, so all being well I should have that next weekend....
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Hopefully things will go better next weekend and I can get the engine mounts beefed up and the engine finally mounted in the chassis.
Sera
http://www.motosera.com
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FASTdan
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| posted on 10/2/10 at 01:25 PM |
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quote:
Originally posted by flak monkey
Very little progress this week. Crap week at work hasnt really put me in the best frame of mind for working on the car.
All looking good - what do you do out of interest? I only ask as I assume design engineer perhaps? given the cad and general engineering knowhow.
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NOTE:This user is registered as a LocostBuilders trader and may offer commercial services to other users
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flak monkey
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| posted on 10/2/10 at 01:59 PM |
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I work as a project engineer, but am also getting more involved in production management more and more every day it seems....
The last couple of weeks have been hell as we had a load of machines down, but things seem to be picking up now *touch wood*
Sera
http://www.motosera.com
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dlatch
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| posted on 10/2/10 at 04:20 PM |
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that rad looks absolutley perfect
i dread to think but how much?
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FASTdan
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| posted on 10/2/10 at 09:45 PM |
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quote:
Originally posted by flak monkey
I work as a project engineer, but am also getting more involved in production management more and more every day it seems....
The last couple of weeks have been hell as we had a load of machines down, but things seem to be picking up now *touch wood*
Same here (project engineer). What do you make/design/build? We do special purpose machinery for the food and process industry (tobacco,
pharmaceuticals etc).
NEW danST WEBSITE NOW LIVE! Bike carbs, throttle bodies and more......
http://www.danstengineering.co.uk/
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NOTE:This user is registered as a LocostBuilders trader and may offer commercial services to other users
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flak monkey
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| posted on 10/2/10 at 10:03 PM |
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I work for a specialist bearing company. The projects are varied, I usually get involved in procuring new machinery rather than the site improvement
stuff. That includes everything from selecting the kit, justifying it, sorting tooling, capability trials, training, and long term support to the shop
floor. The machinery can be anything from £2k wash tanks to £250k+ grinders.
I also am responsible for the technical side of 6 manufacturing areas (3 turning (upto around 500mm dia) 2 grinding and hardturning (internal and
external) and the raw material cut off). If any of the areas have any technical problems they come and see me... so its pretty varied, but when
machines are out of action it becomes a nightmare.
Anyway as this is starting to sound like a CV....
GRS have just sent some more piccies of the radiator and intercooler over for my perusal Looks like its coming on well. Theres just the tight 90deg
50mm tubes to weld on by the looks of it. The intercooler is 50mm core, and bolts to the front of the radiator. I will fit some strips top and bottom
to force any air that goes through the intercooler to pass through the radiator too...unless GRS beat me to it
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And no its not cheap But should be more than adequate!
Sera
http://www.motosera.com
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flak monkey
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| posted on 13/2/10 at 09:10 PM |
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Made a little more progress yesterday, and dropped the engine and gearbox in finally tonight. Need to torque the bellhouing bolts, but access is
easy.
Welded in some additional plates on the chassis, the intention being that tomorrow I will be spending the day beefing up the engine mounts by adding
in another tube and rubber mount on each one.
 
Mount plates 1
 
Mount plates 2
Drilled the hole in the bulkhead for the clutch master cylinder. Should give a pedal ratio of around 4.5:1 which should give a light enough pedal and
progressive clutch hopefully! Though yet to try it out...
Also made a new brake pipe to avoid the master cylinder and tidy it all up a bit as I never was happy with the original pipe work.
 
Clutch cylinder mount and new
Got the new prop fitted as well. Went for a heavy duty one from Dunning and Fairbank. Highly recommended, quick turn around (1 week) and beat everyone
else on price
 
New prop 1
Thankfully theres loads of clearance between the supercharger and the column now, around 15mm all around.
 
Column clearance
Fitted the oil filter as well so I know how much room I have for the engine mount modifications. Thankfully there's plenty of room around
there.
 
Oil filter fitted
Also looks like my intercooler and rad is nearly finished by the pics I have just had from GRS
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Sera
http://www.motosera.com
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goaty
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| posted on 14/2/10 at 10:20 AM |
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looks very good, how tall is the cooler ocmplete with the pipe connections, they look like they poke up quite high.....worried abotu how tight it will
be.
And i got issues fitting my engine, it dont fit in the bay...lol. Moving some bits of chassis as we speak
you dont realise how tight these engine bays are till you try...lol
Yours is looking very good now david, keep up with the pics etc, wish i'd done the same
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flak monkey
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| posted on 14/2/10 at 07:09 PM |
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The dimensions are as in the drawings, think I posted them earlier in this thread somewhere...
Glad I didnt have to move any chassis rails!
Finished off the engine mounts today after concerns they werent up to the job. Hopefully now they should take the stick!
This pic shows the angle of the mounts from the front
 
Finished engine mounts 1
Passenger side
 
Finished engine mounts 4
Drivers side
 
Finished engine mounts 3
The rad and intercooler are finished too and should be here next week
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Next weekends jobs are mounting the oil cooler for the supercharger. Adding in an additional bolt bracket on the supercharger bracket which will
increase the stiffness of the mount considerably. Mounting the swirl pot and header tank. Connecting up the clutch and checking for leaks. Starting to
suss out the wiring and pipework for the engine bay.
Sera
http://www.motosera.com
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Stuart_B
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| posted on 14/2/10 at 07:23 PM |
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that looks awesome david,
great work
stuart
black mk indy, 1.6pinto on cbr600 bike carb's.
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goaty
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| posted on 14/2/10 at 08:36 PM |
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that does look amazing. cant wait for mine
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flak monkey
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| posted on 17/2/10 at 09:57 PM |
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Modded the throttle bodies tonight to give me a point to take a MAP signal from each. Oddly most off the shelf throttle bodies seem to only come with
TPS as standard and no option for map.
Nerve racking drilling into several hundred quids worth of throttle bodies, but there we go...
Fitted an M5 threaded, 4mm hose tail into each port. Sealed in with Loctite 542 thread sealant.
Once modded they were fitted up again, and hopefully wont be coming off again any time soon Throttle stops all set and locked off too to cosworths
recommended base settings.
 
Throttle body mods 1
 
Throttle body mods 2
 
Throttle body mods 3
 
Throttle body mods 14
 
Throttle body mods 5
Sera
http://www.motosera.com
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goaty
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| posted on 17/2/10 at 10:28 PM |
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looks briliant, not sure if i woudl be brave enough..lol. Are you going to run them to a little break tank or just tee them straight to the map
sensor??
Some seem to use a little tank to loose any chance of pulses....
wont be long till she runs
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flak monkey
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| posted on 18/2/10 at 08:53 PM |
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I will probably run them to a small tank as I need to split the MAP signal between the ECU, fuel pressure regulator and dump valve...
Getting a bit worried about progress at the moment, as I need to get enough time in to get it mapped on the road before stoneleigh otherwise
I'll be in the tintop
Sera
http://www.motosera.com
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Steve Hignett
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| posted on 18/2/10 at 08:58 PM |
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quote:
Originally posted by flak monkeyotherwise I'll be in the tintop
Don't even think it...
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goaty
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| posted on 18/2/10 at 09:42 PM |
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lol, i am sure you will make it, unfortunately i am garunteed to be in tin top, bt am awiting a peek at yours
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matt.c
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| posted on 18/2/10 at 10:35 PM |
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Great progress flak. Have you thought about fitting a full fire extinguisher system? Wouldnt want a small leak to end in disaster!
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