tag:blogger.com,1999:blog-18245019154302723632024-03-12T20:56:56.524-07:00 - Ferotus V8 Exige -Anonymoushttp://www.blogger.com/profile/03336342366242553292noreply@blogger.comBlogger88125tag:blogger.com,1999:blog-1824501915430272363.post-18305431507544928572016-05-16T01:06:00.000-07:002016-05-16T01:06:04.631-07:00Engine Calibration development ongoing...<div class="separator" style="clear: both; text-align: center;">
<span style="font-family: "Trebuchet MS", sans-serif; font-size: x-small;"><iframe width="320" height="266" class="YOUTUBE-iframe-video" data-thumbnail-src="https://i.ytimg.com/vi/bas-tYJO3xA/0.jpg" src="https://www.youtube.com/embed/bas-tYJO3xA?feature=player_embedded" frameborder="0" allowfullscreen></iframe></span></div>
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<span style="font-family: "Trebuchet MS", sans-serif; font-size: x-small;">Getting there, still some work to do before final mapping but I'm hopeful I'll be able to drive it up and down my driveway shortly..</span></div>
<br />Unknownnoreply@blogger.com0tag:blogger.com,1999:blog-1824501915430272363.post-30119062755262179822016-03-19T14:25:00.000-07:002016-03-19T14:25:59.371-07:00Clutch & Flywheel<span style="font-family: Trebuchet MS, sans-serif; font-size: x-small;">Apologies for the time since the last post. I'm making up for it though with my longest post to date. </span><br />
<span style="font-family: Trebuchet MS, sans-serif; font-size: x-small;"><br /></span>
<span style="font-family: Trebuchet MS, sans-serif; font-size: x-small;">------------------------------------------------------------------</span><br />
<span style="font-family: Trebuchet MS, sans-serif; font-size: x-small;"><br /></span>
<span style="font-family: Trebuchet MS, sans-serif; font-size: x-small;">So another area I'd identified for improvement on the car is the clutch and flywheel.</span><br />
<span style="font-family: Trebuchet MS, sans-serif; font-size: x-small;"><br /></span>
<span style="font-family: Trebuchet MS, sans-serif; font-size: x-small;">As standard the F355 ran a dual mass flywheel, probably one of the earlier applications on a high performance car. The two elements inside the DMF are torsionally damped by some sprung elements, but also by a special Kluber grease. The cars are notorious for problems when the grease has either liquified from a gearbox oil leak from the 'triple seal' on the transfer shaft, or solidified through absorption of dust and other debris.</span><br />
<span style="font-family: Trebuchet MS, sans-serif; font-size: x-small;"><br /></span>
<span style="font-family: Trebuchet MS, sans-serif; font-size: x-small;">In order to avoid these issues on my 2nd hand 'box (and because I spotted room for a very significant weight saving) I decided to switch to a traditional single mass, lightened flywheel, with a sprung-centre paddle clutch (the standard F355 friction plate is not sprung as it is assumed the DMF does all the torsional damping).</span><br />
<span style="font-family: Trebuchet MS, sans-serif; font-size: x-small;"><br /></span>
<span style="font-family: Trebuchet MS, sans-serif; font-size: x-small;">I also swapped out the F355 solid transfer shaft for one from the Ferrari 348 which is gundrilled from both ends and 30% lighter.</span><br />
<span style="font-family: Trebuchet MS, sans-serif; font-size: x-small;"><br /></span>
<span style="font-family: Trebuchet MS, sans-serif; font-size: x-small;">The flywheel and clutch were provided (with great service) by MD Clutches (link on my links page). The flywheel is completely custom and nearly 50% lighter. The sprung clutch is adapted from a Ferrari 360 unit.</span><br />
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<a href="https://1.bp.blogspot.com/-YMYlFY5ii44/Vu3B2onHrhI/AAAAAAAABKk/nP32EZy_kx4K1749sJNbndTf69IfYj89g/s1600/IMG_20160319_082227.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="320" src="https://1.bp.blogspot.com/-YMYlFY5ii44/Vu3B2onHrhI/AAAAAAAABKk/nP32EZy_kx4K1749sJNbndTf69IfYj89g/s320/IMG_20160319_082227.jpg" width="192" /></a><a href="https://2.bp.blogspot.com/-YMPpXGR5F5o/Vu3B2y8AR0I/AAAAAAAABKo/kTdhYgFBf3YswAfl7fwJSF3avyajY7RoA/s1600/IMG_20160319_082408.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="210" src="https://2.bp.blogspot.com/-YMPpXGR5F5o/Vu3B2y8AR0I/AAAAAAAABKo/kTdhYgFBf3YswAfl7fwJSF3avyajY7RoA/s320/IMG_20160319_082408.jpg" width="320" /></a></div>
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<a href="https://1.bp.blogspot.com/-CzmpLzetVgE/Vu3B4Z__r3I/AAAAAAAABKs/kW8sXImHhm4-7q9R4WN40nYs9JiANfeag/s1600/IMG_20160319_082702.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="226" src="https://1.bp.blogspot.com/-CzmpLzetVgE/Vu3B4Z__r3I/AAAAAAAABKs/kW8sXImHhm4-7q9R4WN40nYs9JiANfeag/s320/IMG_20160319_082702.jpg" width="320" /></a></div>
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<span style="font-family: Trebuchet MS, sans-serif; font-size: x-small;">The pressure plate and all the clutch release gubbins are carried over, and I swapped in some Ti bolts for added intertia savings on the pressure plate.</span><br />
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<a href="https://2.bp.blogspot.com/-g5Vqt4-ACWE/Vu3CV6QyQ4I/AAAAAAAABK4/aPsC8h9OdoAMLR-nZh4XEAeVGcFo74jqA/s1600/DSC_3131.JPG" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="320" src="https://2.bp.blogspot.com/-g5Vqt4-ACWE/Vu3CV6QyQ4I/AAAAAAAABK4/aPsC8h9OdoAMLR-nZh4XEAeVGcFo74jqA/s320/DSC_3131.JPG" width="180" /></a></div>
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<span style="font-family: Trebuchet MS, sans-serif; font-size: x-small;"><br /></span>
<span style="font-family: Trebuchet MS, sans-serif; font-size: x-small;">The total weight savings look like this:</span><br />
<span style="font-family: Trebuchet MS, sans-serif; font-size: x-small;"><br /></span>
<table border="0" cellpadding="0" cellspacing="0" style="border-collapse: collapse; text-align: center; width: 372px;">
<colgroup><col style="mso-width-alt: 3986; mso-width-source: userset; width: 82pt;" width="109"></col>
<col style="mso-width-alt: 2230; mso-width-source: userset; width: 46pt;" width="61"></col>
<col style="width: 48pt;" width="64"></col>
<col style="mso-width-alt: 2706; mso-width-source: userset; width: 56pt;" width="74"></col>
<col style="width: 48pt;" width="64"></col>
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<tr height="20" style="height: 15.0pt;">
<td height="20" style="height: 15.0pt; width: 82pt;" width="109"></td>
<td style="width: 46pt;" width="61"><span style="font-family: Trebuchet MS, sans-serif; font-size: x-small;">Old (g)</span></td>
<td style="width: 48pt;" width="64"><span style="font-family: Trebuchet MS, sans-serif; font-size: x-small;">New (g)</span></td>
<td style="width: 56pt;" width="74"><span style="font-family: Trebuchet MS, sans-serif; font-size: x-small;">saving (g)</span></td>
<td style="width: 48pt;" width="64"><span style="font-family: Trebuchet MS, sans-serif; font-size: x-small;">%</span></td>
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<td height="20" style="height: 15.0pt;"><span style="font-family: Trebuchet MS, sans-serif; font-size: x-small;">friction plate</span></td>
<td class="xl65" style="text-align: right;"><span style="font-family: Trebuchet MS, sans-serif; font-size: x-small;">1163</span></td>
<td class="xl65" style="border-left-style: none; text-align: right;"><span style="font-family: Trebuchet MS, sans-serif; font-size: x-small;">1919</span></td>
<td class="xl65" style="border-left-style: none; text-align: right;"><span style="font-family: Trebuchet MS, sans-serif; font-size: x-small;">-756</span></td>
<td class="xl66" style="border-left-style: none; text-align: right;"><span style="font-family: Trebuchet MS, sans-serif; font-size: x-small;">165.0%</span></td>
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<td height="20" style="height: 15.0pt;"><span style="font-family: Trebuchet MS, sans-serif; font-size: x-small;">M6 bolts</span></td>
<td class="xl65" style="border-top-style: none; text-align: right;"><span style="font-family: Trebuchet MS, sans-serif; font-size: x-small;">88</span></td>
<td class="xl65" style="border-left-style: none; border-top-style: none; text-align: right;"><span style="font-family: Trebuchet MS, sans-serif; font-size: x-small;">45</span></td>
<td class="xl65" style="border-left-style: none; border-top-style: none; text-align: right;"><span style="font-family: Trebuchet MS, sans-serif; font-size: x-small;">43</span></td>
<td class="xl66" style="border-left-style: none; border-top-style: none; text-align: right;"><span style="font-family: Trebuchet MS, sans-serif; font-size: x-small;">51.1%</span></td>
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<tr height="20" style="height: 15.0pt;">
<td height="20" style="height: 15.0pt;"><span style="font-family: Trebuchet MS, sans-serif; font-size: x-small;">shaft</span></td>
<td class="xl65" style="border-top-style: none; text-align: right;"><span style="font-family: Trebuchet MS, sans-serif; font-size: x-small;">1828</span></td>
<td class="xl65" style="border-left-style: none; border-top-style: none; text-align: right;"><span style="font-family: Trebuchet MS, sans-serif; font-size: x-small;">1292</span></td>
<td class="xl65" style="border-left-style: none; border-top-style: none; text-align: right;"><span style="font-family: Trebuchet MS, sans-serif; font-size: x-small;">536</span></td>
<td class="xl66" style="border-left-style: none; border-top-style: none; text-align: right;"><span style="font-family: Trebuchet MS, sans-serif; font-size: x-small;">70.7%</span></td>
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<td height="20" style="height: 15.0pt;"><span style="font-family: Trebuchet MS, sans-serif; font-size: x-small;">flywheel</span></td>
<td class="xl65" style="border-top-style: none; text-align: right;"><span style="font-family: Trebuchet MS, sans-serif; font-size: x-small;">10700</span></td>
<td class="xl65" style="border-left-style: none; border-top-style: none; text-align: right;"><span style="font-family: Trebuchet MS, sans-serif; font-size: x-small;">5726</span></td>
<td class="xl65" style="border-left-style: none; border-top-style: none; text-align: right;"><span style="font-family: Trebuchet MS, sans-serif; font-size: x-small;">4974</span></td>
<td class="xl66" style="border-left-style: none; border-top-style: none; text-align: right;"><span style="font-family: Trebuchet MS, sans-serif; font-size: x-small;">53.5%</span></td>
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<td height="20" style="height: 15.0pt;"><span style="font-family: Trebuchet MS, sans-serif; font-size: x-small;">pressure plate</span></td>
<td class="xl65" style="border-top-style: none; text-align: right;"><span style="font-family: Trebuchet MS, sans-serif; font-size: x-small;">4658</span></td>
<td class="xl65" style="border-left-style: none; border-top-style: none; text-align: right;"><span style="font-family: Trebuchet MS, sans-serif; font-size: x-small;">4658</span></td>
<td class="xl65" style="border-left-style: none; border-top-style: none; text-align: right;"><span style="font-family: Trebuchet MS, sans-serif; font-size: x-small;">0</span></td>
<td class="xl66" style="border-left-style: none; border-top-style: none; text-align: right;"><span style="font-family: Trebuchet MS, sans-serif; font-size: x-small;">100.0%</span></td>
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<td height="20" style="height: 15.0pt;"></td>
<td></td>
<td></td>
<td></td>
<td></td>
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<tr height="20" style="height: 15.0pt;">
<td height="20" style="height: 15.0pt;"></td>
<td style="text-align: right;"><span style="font-family: Trebuchet MS, sans-serif; font-size: x-small;">18437</span></td>
<td style="text-align: right;"><span style="font-family: Trebuchet MS, sans-serif; font-size: x-small;">13640</span></td>
<td style="text-align: right;"><span style="font-family: Trebuchet MS, sans-serif; font-size: x-small;">4797</span></td>
<td class="xl64" style="text-align: right;"><span style="font-family: Trebuchet MS, sans-serif; font-size: x-small;">73.98%</span></td>
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<span style="font-family: Trebuchet MS, sans-serif; font-size: x-small;"><br /></span><div>
<span style="font-family: Trebuchet MS, sans-serif; font-size: x-small;">I also put some work into the clutch cover. I'm becoming pretty blasé to taking an angle grinder to Ferrari components now, which I'm not sure is a good thing!</span></div>
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<span style="font-family: Trebuchet MS, sans-serif; font-size: x-small;">Anyway another 250g saved and I'm very pleased with how it came out. :-)</span></div>
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<span style="font-family: Trebuchet MS, sans-serif; font-size: x-small;"><br /></span></div>
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<span style="font-family: Trebuchet MS, sans-serif; font-size: x-small;">Overall 5050 grams saved. 4800 of them rotating mass, and all of them hung out behind the rear axle!</span></div>
Unknownnoreply@blogger.com0tag:blogger.com,1999:blog-1824501915430272363.post-89522932383108068922016-02-07T09:30:00.003-08:002016-02-07T09:30:57.498-08:00Software & setup - Part II<div class="separator" style="clear: both; text-align: center;">
<span style="font-family: Trebuchet MS, sans-serif; font-size: x-small;"><br /></span></div>
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<span style="font-family: Trebuchet MS, sans-serif; font-size: x-small;">So continued I playing with the software until after a couple of days I got this:</span></div>
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<span style="font-family: Trebuchet MS, sans-serif; font-size: x-small;">Very quickly followed by this:</span></div>
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<span style="font-family: Trebuchet MS, sans-serif; font-size: x-small;">(apologies it's so dark, I just moves to a new house and while the garage is bigger it is very poorly lit at the moment. 4 big striplights are an urgent necessity!)</span></div>
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<a href="https://2.bp.blogspot.com/-slOo4xous0o/Vrd-f3voSgI/AAAAAAAABI8/KVcfpR5EGI4/s1600/IMG_20160206_080849.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><span style="font-family: Trebuchet MS, sans-serif; font-size: x-small;"><img border="0" height="185" src="https://2.bp.blogspot.com/-slOo4xous0o/Vrd-f3voSgI/AAAAAAAABI8/KVcfpR5EGI4/s320/IMG_20160206_080849.jpg" width="320" /></span></a></div>
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<span style="font-family: Trebuchet MS, sans-serif; font-size: x-small;">While the engine is running you can view all channels and parameters live in CalTool. Getting a nice healthy 6.8bar of oil pressure at cold idle.</span></div>
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<a href="https://2.bp.blogspot.com/-XoNGAZkEUnA/Vrd-fali02I/AAAAAAAABI4/dgKhKCZ8ff4/s1600/IMG_20160206_081228.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><span style="font-family: Trebuchet MS, sans-serif; font-size: x-small;"><img border="0" height="216" src="https://2.bp.blogspot.com/-XoNGAZkEUnA/Vrd-fali02I/AAAAAAAABI4/dgKhKCZ8ff4/s320/IMG_20160206_081228.jpg" width="320" /></span></a></div>
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<span style="font-family: Trebuchet MS, sans-serif; font-size: x-small;">Dropping to around 3.2bar at hot idle.</span></div>
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<span style="font-family: Trebuchet MS, sans-serif; font-size: x-small;">Next jobs are to iron out a few niggles with the control of fuelpump and waterpump, do an oil flush and filter change, then I can begin refining and mapping the base calibration. </span></div>
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<br />Unknownnoreply@blogger.com0tag:blogger.com,1999:blog-1824501915430272363.post-14985316188234537442016-01-31T12:03:00.003-08:002016-01-31T12:03:51.681-08:00Software setup - Part I<span style="font-family: Trebuchet MS, sans-serif; font-size: x-small;">Now we are onto the engine software and hardware set-up bit. Sensor calibrations, strategy writing and ultimately engine firing for the first time hopefully. </span><br />
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<span style="font-family: Trebuchet MS, sans-serif; font-size: x-small;">The software we are using is CalTool from Pi (Cosworth).</span><br />
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<span style="font-family: Trebuchet MS, sans-serif; font-size: x-small;">There are literally thousands and thousands of functions, 90% are not needed for my application. Here's just a few screengrabs to give you an idea of what we are working with at the moment...</span><br />
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<a href="http://3.bp.blogspot.com/-LBBZrFABHcc/Vq5n0MMr62I/AAAAAAAABIU/pKJVBThWFM4/s1600/caltool1.png" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="200" src="http://3.bp.blogspot.com/-LBBZrFABHcc/Vq5n0MMr62I/AAAAAAAABIU/pKJVBThWFM4/s320/caltool1.png" width="320" /></a></div>
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<span style="font-family: Trebuchet MS, sans-serif; font-size: x-small;">We have sucessfully tested the PWM fuel pump control. Here's an overview of the parameters!!</span></div>
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<a href="http://3.bp.blogspot.com/-NuyhM6ooe44/Vq5n0sNZ6xI/AAAAAAAABIc/JB2NMBJzXM8/s1600/caltool2.png" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="200" src="http://3.bp.blogspot.com/-NuyhM6ooe44/Vq5n0sNZ6xI/AAAAAAAABIc/JB2NMBJzXM8/s320/caltool2.png" width="320" /></a></div>
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<a href="http://3.bp.blogspot.com/-QlyYMblAGPU/Vq5n0MOZRtI/AAAAAAAABIY/dYWE9AjHITg/s1600/caltool%2Bpwm2.png" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="320" src="http://3.bp.blogspot.com/-QlyYMblAGPU/Vq5n0MOZRtI/AAAAAAAABIY/dYWE9AjHITg/s320/caltool%2Bpwm2.png" width="232" /></a></div>
<br />Unknownnoreply@blogger.com0tag:blogger.com,1999:blog-1824501915430272363.post-8594317544964391772016-01-11T12:28:00.000-08:002016-01-11T13:11:32.734-08:00Chassis, Dash & Comms - Part II<span style="font-family: Trebuchet MS, sans-serif; font-size: x-small;"><br /></span>
<span style="font-family: Trebuchet MS, sans-serif; font-size: x-small;">So following on from the last post, here's pics of all the loom forward of the bulkhead fitted to the car. </span><br />
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<span style="font-family: Trebuchet MS, sans-serif; font-size: x-small;">It all went together exactly as planned which is nice.</span><br />
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<a href="http://2.bp.blogspot.com/-7V71c4sIl1Y/VpQLzL1mF-I/AAAAAAAABE4/rjxMuiicwgU/s1600/DSC_0112.JPG" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><span style="font-family: Trebuchet MS, sans-serif; font-size: x-small;"><img border="0" height="180" src="http://2.bp.blogspot.com/-7V71c4sIl1Y/VpQLzL1mF-I/AAAAAAAABE4/rjxMuiicwgU/s320/DSC_0112.JPG" width="320" /></span></a></div>
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<span style="font-family: Trebuchet MS, sans-serif; font-size: x-small;"> Main bulkhead connector from rear.</span></div>
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<a href="http://3.bp.blogspot.com/-et3ykhG0xgI/VpQL8RIk1KI/AAAAAAAABFQ/qDWKpJkKrNw/s1600/IMG_20160110_180124.jpg" imageanchor="1" style="clear: left; float: left; margin-bottom: 1em; margin-right: 1em;"></a><a href="https://1.bp.blogspot.com/--wtqduxknX0/VpQL9JvXjVI/AAAAAAAABFY/5scev8Thu8s/s1600/IMG_20160110_180439.jpg" imageanchor="1" style="clear: left; float: left; margin-bottom: 1em; margin-right: 1em;"><img border="0" height="240" src="http://1.bp.blogspot.com/--wtqduxknX0/VpQL9JvXjVI/AAAAAAAABFY/5scev8Thu8s/s320/IMG_20160110_180439.jpg" width="320" /></a><img border="0" height="188" src="http://3.bp.blogspot.com/-et3ykhG0xgI/VpQL8RIk1KI/AAAAAAAABFQ/qDWKpJkKrNw/s200/IMG_20160110_180124.jpg" width="200" /><span style="font-family: Trebuchet MS, sans-serif; font-size: x-small; margin-left: 1em; margin-right: 1em;"></span></div>
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<span style="font-family: Trebuchet MS, sans-serif; font-size: x-small;">Bulkhead connector, ECU, starter and fuel pump driver module relays mounted to front of bulkhead.</span></div>
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<span style="font-family: Trebuchet MS, sans-serif; font-size: x-small;">Dash area starting to look neater now..</span></div>
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<span style="font-family: Trebuchet MS, sans-serif; font-size: x-small;">Powering up for the first time:</span><br />
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<a href="http://3.bp.blogspot.com/-Nhej97u112w/VpQLy5OX5JI/AAAAAAAABEw/BcNn4C8AGjw/s1600/DSC_0128.JPG" imageanchor="1" style="clear: left; float: left; margin-bottom: 1em; margin-right: 1em;"><img border="0" height="180" src="http://3.bp.blogspot.com/-Nhej97u112w/VpQLy5OX5JI/AAAAAAAABEw/BcNn4C8AGjw/s320/DSC_0128.JPG" width="320" /></a><a href="http://1.bp.blogspot.com/-VdO4klOYWjA/VpQMAqk-EhI/AAAAAAAABFo/xO1FEe0xxZg/s1600/IMG_20160111_194216.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="272" src="http://1.bp.blogspot.com/-VdO4klOYWjA/VpQMAqk-EhI/AAAAAAAABFo/xO1FEe0xxZg/s320/IMG_20160111_194216.jpg" width="320" /></a></div>
<br />Unknownnoreply@blogger.com2tag:blogger.com,1999:blog-1824501915430272363.post-10814713013120875492016-01-08T07:37:00.002-08:002016-01-08T07:37:36.894-08:00Chassis, Dash & Comms loom - Part I<div class="separator" style="clear: both; text-align: center;">
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<span style="font-family: Trebuchet MS, sans-serif; font-size: x-small;">Will be spending all weekend fitting the chassis loom, relays and ECU to the cockpit. the ECU and three relays pictured in the first image below will live on the inside of the bulkhead.</span></div>
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<a href="http://4.bp.blogspot.com/-CLMs0n3ZGcI/Vo_XDWaEI1I/AAAAAAAABD0/_MGUE6o3VQE/s1600/IMG-20160107-WA0001.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><span style="font-family: Trebuchet MS, sans-serif; font-size: x-small;"><img border="0" height="180" src="http://4.bp.blogspot.com/-CLMs0n3ZGcI/Vo_XDWaEI1I/AAAAAAAABD0/_MGUE6o3VQE/s320/IMG-20160107-WA0001.jpg" width="320" /></span></a></div>
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<span style="font-family: Trebuchet MS, sans-serif; font-size: x-small;">The other 3 relays will live in the space under the standard S1 dash top, which is rather cavernous. </span></div>
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<a href="http://4.bp.blogspot.com/-S-GN2shp7M8/Vo_XDfUPVpI/AAAAAAAABD4/9aihv0_9fWM/s1600/IMG-20160107-WA0002.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><span style="font-family: Trebuchet MS, sans-serif; font-size: x-small;"><img border="0" height="180" src="http://4.bp.blogspot.com/-S-GN2shp7M8/Vo_XDfUPVpI/AAAAAAAABD4/9aihv0_9fWM/s320/IMG-20160107-WA0002.jpg" width="320" /></span></a></div>
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<span style="font-family: Trebuchet MS, sans-serif; font-size: x-small;">Sub-loom for Omega Digital Dash (means that future upgrade/change of dash type is more straightforward)</span></div>
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<a href="http://2.bp.blogspot.com/-bUTG9EKUtzo/Vo_XEP9IF2I/AAAAAAAABEA/z5Eke88tRRM/s1600/IMG-20160108-WA0000.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><span style="font-family: Trebuchet MS, sans-serif; font-size: x-small;"><img border="0" height="180" src="http://2.bp.blogspot.com/-bUTG9EKUtzo/Vo_XEP9IF2I/AAAAAAAABEA/z5Eke88tRRM/s320/IMG-20160108-WA0000.jpg" width="320" /></span></a></div>
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Unknownnoreply@blogger.com0tag:blogger.com,1999:blog-1824501915430272363.post-26391236516296154212016-01-01T06:23:00.002-08:002016-01-01T06:34:27.907-08:00New Year's day updates!<span style="font-family: Trebuchet MS, sans-serif; font-size: x-small;">Happy New Year everyone. I'm looking forward to 2016 as the year to finally get the car finished and go out and enjoy using it! :-)</span><br />
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<span style="font-family: Trebuchet MS, sans-serif; font-size: x-small;">I've had a very productive couple of weeks on the car, in no particular order:</span><br />
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<li><span style="font-family: Trebuchet MS, sans-serif; font-size: x-small;"><b>Engine loom installed</b>. Hole drilled for bulkhead connector to chassis/cockpit side loom.</span></li>
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<li><span style="font-family: Trebuchet MS, sans-serif; font-size: x-small;"><b>Brakes bled.</b> Initially we had a slightly spongy pedal but tracked this down to some slight play in the hydraulic handbrake mech. Once I rectified this the pedal feels great. I am hopeful the brake performance and bias will be pretty good out of the box.</span></li>
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<li><span style="font-family: Trebuchet MS, sans-serif; font-size: x-small;"><b>Clutch bled.</b> Got lucky with this one and the matching of standard S1 lotus master cylinder to standard Ferrari slave cylinder has turned out to give an almost perfect pedal feel and weight. The clutch seems to engage and disengage smoothly. I believe the plates have only 17,000 miles on so hopefully there is a goo bit of life left in it yet.</span></li>
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<li><span style="font-family: Trebuchet MS, sans-serif; font-size: x-small;"><b>Rear wing endplates made</b>. I had been holding off on this as I couldn't decide what to make these out of. In the end I plumped for the same ABS-based material I've used for the side skirts. The only downside of this material is I can't quite figure out how I'm going to create the louvres we want. More thinking required..!! (but they will do for now!). The geometry of the endplates has been suggested by a friend of mine who is an aerodynamicist for Williams F1 team.</span></li>
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<li><span style="font-family: Trebuchet MS, sans-serif; font-size: x-small;"><b>Diffuser consctuction</b>. Started out by extending the standard S1 elise diffuser and using that as template. Will do a full post on the diffuser once it's complete...</span></li>
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Unknownnoreply@blogger.com0tag:blogger.com,1999:blog-1824501915430272363.post-56475546253546177082015-12-24T03:06:00.001-08:002015-12-24T03:06:17.963-08:00Loom Part II<div class="separator" style="clear: both; text-align: center;">
<a href="http://4.bp.blogspot.com/-rzQVCqg2bTk/VnvQ7BXzTRI/AAAAAAAABAo/FATSgKPF9zg/s1600/_20151224_110057.JPG" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="320" src="http://4.bp.blogspot.com/-rzQVCqg2bTk/VnvQ7BXzTRI/AAAAAAAABAo/FATSgKPF9zg/s320/_20151224_110057.JPG" width="297" /></a></div>
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<span style="font-family: Trebuchet MS, sans-serif; font-size: x-small;">Engine loom is now complete and I will be fitting over the Christmas break. Fully sheathed in Raychem DR25, labelled and with Milspec weatherproof connectors throughout. </span></div>
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<span style="font-family: Trebuchet MS, sans-serif; font-size: x-small;">Merry Christmas everyone!</span></div>
<br />Unknownnoreply@blogger.com0tag:blogger.com,1999:blog-1824501915430272363.post-17484909687356400902015-12-11T14:47:00.003-08:002015-12-11T14:47:27.427-08:00Engine,dash & comms loom (Part I)<span style="font-family: Trebuchet MS, sans-serif; font-size: x-small;">Sorry for the lack of updates. It's been a month since my last post, but to be honest it feels like not a lot has happened on the car in that time. :-(</span><br />
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<span style="font-family: Trebuchet MS, sans-serif; font-size: x-small;">I have been waiting on the CNC machining of the front brake calipers (will post on these shortly as I have one of them now) before I can bleed the brakes and clutch.</span><br />
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<span style="font-family: Trebuchet MS, sans-serif; font-size: x-small;">And I have been waiting on completion of the engine, dash and ECU comms loom.</span><br />
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<span style="font-family: Trebuchet MS, sans-serif; font-size: x-small;">Obviously both of these are needed before I can try to start the engine and take the car for mapping. I have seen the loom and it's at least 75% complete, hopefully I will have it in the next week or so. In the meantime here's a few pictures of work in progress and bench testing the Cosworth Omega D1 dash:</span><br />
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<a href="http://3.bp.blogspot.com/-oGLFfPPxhcM/VmtNnVrmhyI/AAAAAAAAA_8/gcM2-A_KzJM/s1600/IMG-20151006-WA0000.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="320" src="http://3.bp.blogspot.com/-oGLFfPPxhcM/VmtNnVrmhyI/AAAAAAAAA_8/gcM2-A_KzJM/s320/IMG-20151006-WA0000.jpg" width="180" /></a><a href="http://1.bp.blogspot.com/-vK2BYPe4FXU/VmtNsPANnGI/AAAAAAAABAU/Aj-Bx_FZUEo/s1600/IMG-20151006-WA0001%257E2.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="320" src="http://1.bp.blogspot.com/-vK2BYPe4FXU/VmtNsPANnGI/AAAAAAAABAU/Aj-Bx_FZUEo/s320/IMG-20151006-WA0001%257E2.jpg" width="180" /></a></div>
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<span style="background-color: #f6f7f8; color: #141823; line-height: 16.08px; text-align: left;"><span style="font-family: Trebuchet MS, sans-serif; font-size: x-small;">Green = injectors. Blue = coils. White = sensor inputs. Pink 0V. Orange 5V. Red 12V... etc etc :-)</span></span></div>
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<a href="http://3.bp.blogspot.com/-BIyqH9r2BVY/VmtNnbEL8GI/AAAAAAAABAA/j_i_ijuwv6Q/s1600/IMG-20151208-WA0000.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="180" src="http://3.bp.blogspot.com/-BIyqH9r2BVY/VmtNnbEL8GI/AAAAAAAABAA/j_i_ijuwv6Q/s320/IMG-20151208-WA0000.jpg" width="320" /></a></div>
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<a href="http://4.bp.blogspot.com/-bLGd0kWy39A/VmtNn8SeGiI/AAAAAAAABAE/cppVrQl5d3g/s1600/IMG-20151208-WA0001.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="180" src="http://4.bp.blogspot.com/-bLGd0kWy39A/VmtNn8SeGiI/AAAAAAAABAE/cppVrQl5d3g/s320/IMG-20151208-WA0001.jpg" width="320" /></a></div>
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<span style="font-family: Trebuchet MS, sans-serif; font-size: x-small;">Omega D1 with shift light module</span></div>
<br />Unknownnoreply@blogger.com0tag:blogger.com,1999:blog-1824501915430272363.post-19505172250732666992015-11-11T11:18:00.001-08:002015-11-11T11:21:32.693-08:00back on the ground!<span style="font-family: "trebuchet ms" , sans-serif; font-size: x-small;"><br /></span>
<span style="font-family: "trebuchet ms" , sans-serif; font-size: x-small;">So earlier this week, after precisely 521 days on axle stands since I started stripping the original S1 Elise the car is back on it's own four patches of rubber. </span><br />
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<span style="font-family: "trebuchet ms" , sans-serif; font-size: x-small;">Looking at how the car has metamorphisied (!) over that time I'm pretty pleased with the outcome and timescale. Especially seeing as I set out stripping the Elise without a clear plan as to what powerplant was going in at the time.</span><br />
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<span style="font-family: "trebuchet ms" , sans-serif; font-size: x-small;">So still outstanding now are mainly just the fitment of the bespoke motorsport spec wiring loom, which isn't quite complete yet, fitment of front brake calipers and bleeding of clutch and brakes, and then set-up and mapping of the engine and all the ancillary systems.</span><br />
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<span style="font-family: "trebuchet ms" , sans-serif; font-size: x-small;">There are quite a few niggly bits and bobs still to address on top of that, but not a lot else that would stop me shaking down the car.</span><br />
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<span style="font-family: "trebuchet ms" , sans-serif; font-size: x-small;">Here's some pictures of the car back where it belongs :)</span><br />
<span style="font-family: "trebuchet ms" , sans-serif; font-size: x-small;">(ride heights are set pretty high for now in anticipation of loading trailers/ramps/rollers etc during mapping)</span><br />
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<br />Unknownnoreply@blogger.com2tag:blogger.com,1999:blog-1824501915430272363.post-60356047394177608512015-11-08T11:54:00.004-08:002015-11-08T11:58:20.642-08:00Fire Extinguisher<span style="font-family: "trebuchet ms" , sans-serif;"><br /></span>
<span style="font-family: "trebuchet ms" , sans-serif; font-size: x-small;">Despite the fact that I am not building this car to any particular set of rules or regulations, it still seems very sensible to fit a decent fire suppression system in the interests of safety given the completely custom nature of the fuel, exhaust and wiring systems on the car.</span><br />
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<span style="font-family: "trebuchet ms" , sans-serif; font-size: x-small;">I decided to mount the bottle in the front compartment, where I could easily site a 2.3Litre bottle. They system is designed for twin nozzles, and I decided to place both into the engine bay (rather than have one in the cockpit), as the engine bay is a more likely place for fire to breakout. If the system can suppress a fire even if just for long enough for me and a passenger to exit the cockpit then it will have done it's job.</span><br />
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<span style="font-family: "trebuchet ms" , sans-serif; font-size: x-small;">A few pics of the install:</span><br />
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<span style="font-family: "trebuchet ms" , sans-serif; font-size: x-small;"> Centrally mounted pull handle where both driver or passenger can get to it in a hurry.</span></div>
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<span style="font-family: "trebuchet ms" , sans-serif;"><a href="http://1.bp.blogspot.com/-svu4KQGf908/Vj-m8TKX4XI/AAAAAAAAA-Q/flGVlptKifs/s1600/DSCF2975.JPG" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="150" src="http://1.bp.blogspot.com/-svu4KQGf908/Vj-m8TKX4XI/AAAAAAAAA-Q/flGVlptKifs/s200/DSCF2975.JPG" width="200" /></a><a href="http://3.bp.blogspot.com/-CkyrDuh6Z58/Vj-m8ICoaLI/AAAAAAAAA-M/wy3WnlMRL9U/s1600/DSCF2978.JPG" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="150" src="http://3.bp.blogspot.com/-CkyrDuh6Z58/Vj-m8ICoaLI/AAAAAAAAA-M/wy3WnlMRL9U/s200/DSCF2978.JPG" width="200" /></a></span></div>
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<span style="font-family: "trebuchet ms" , sans-serif; font-size: x-small;">One nozzle pointing at LHS bank, the other at RHS bank and oil tank.</span></div>
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<br />Unknownnoreply@blogger.com0tag:blogger.com,1999:blog-1824501915430272363.post-12787515250172570782015-11-04T13:56:00.001-08:002015-11-04T13:56:36.971-08:00Onwards and...onwards and.. onwards!<div class="separator" style="clear: both; text-align: justify;">
<span style="font-family: Trebuchet MS, sans-serif; font-size: x-small;">Apologies for the lack of blog updates. It's been a bit of a long slog recently. Mostly just plugging away at all the small stuff that seems to always need doing at the end of the build, but adds up to take an inordinate amount of time!</span></div>
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<span style="font-family: Trebuchet MS, sans-serif; font-size: x-small;">So a few pics:</span></div>
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<a href="http://2.bp.blogspot.com/-DH-jzim-HgM/Vjp3gF6b9zI/AAAAAAAAA88/H6wQQFqtzfI/s1600/11049642_758275735026_1719392535761888478_n.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="320" src="http://2.bp.blogspot.com/-DH-jzim-HgM/Vjp3gF6b9zI/AAAAAAAAA88/H6wQQFqtzfI/s320/11049642_758275735026_1719392535761888478_n.jpg" width="203" /></a></div>
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<span style="font-family: Trebuchet MS, sans-serif; font-size: x-small;">ECU bracket made for AV mounting the SQ6.</span></div>
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<a href="http://4.bp.blogspot.com/-YmAwxDeNgpI/Vjp3gDgE5ZI/AAAAAAAAA9E/O3eEjzU7ZnE/s1600/12186617_758855637896_2742717283007313255_o.jpg" imageanchor="1" style="clear: right; float: right; margin-bottom: 1em; margin-left: 1em;"><img border="0" height="320" src="http://4.bp.blogspot.com/-YmAwxDeNgpI/Vjp3gDgE5ZI/AAAAAAAAA9E/O3eEjzU7ZnE/s320/12186617_758855637896_2742717283007313255_o.jpg" width="147" /></a><a href="http://3.bp.blogspot.com/-BIKdt9QmWEA/Vjp3gSAUpYI/AAAAAAAAA9A/gUAdNPxwHEM/s1600/12189139_758855573026_3964260629906030371_n.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="320" src="http://3.bp.blogspot.com/-BIKdt9QmWEA/Vjp3gSAUpYI/AAAAAAAAA9A/gUAdNPxwHEM/s320/12189139_758855573026_3964260629906030371_n.jpg" width="310" /></a></div>
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<span style="font-family: Trebuchet MS, sans-serif; font-size: x-small;">Collected my driveshafts that have been custom made by Dave Mac Props in Coventry. 108 lobro inner CVs and 28spline Astra outer CVs. The shafts are provided with a lifetime warranty including motorsport use! If anything fails/wears out it is likely to be an inner CV bearing cage or outer joint, neither of which are not too expensive/troublesome to replace...</span></div>
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<span style="font-family: Trebuchet MS, sans-serif; font-size: x-small;">AP Racing high temperature paint for the rather special brakes...</span></div>
<br />Unknownnoreply@blogger.com0tag:blogger.com,1999:blog-1824501915430272363.post-38950767029861227922015-10-18T12:22:00.003-07:002015-10-18T12:22:51.645-07:00Front uprights<div class="separator" style="clear: both; text-align: justify;">
<span style="font-family: Trebuchet MS, sans-serif; font-size: x-small;">This week my EliseParts race front uprights arrived. Excellent service from EP as always, they even threw in a couple of camber shims in for me as these uprights have additional material removed from the shim face in order to run more negative camber than is possible with stock uprights.</span></div>
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<span style="font-family: Trebuchet MS, sans-serif; font-size: x-small;">The main reason for running these however is that they lower the axle 40mm by re-positioning the hub within the upright. This is by far the best way of lowering an Elise/Exige as it keeps the wishbone angles and roll centres as per how they were intended by Lotus.</span></div>
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<span style="font-family: Trebuchet MS, sans-serif; font-size: x-small;">To go along with the uprights I've replaced all the M10 and M12 nuts on the front and rear ball joints with Grade5 Titanium items. This saves an extra 100g of unsprung weight! :-)</span></div>
<br />Unknownnoreply@blogger.com0tag:blogger.com,1999:blog-1824501915430272363.post-71534375412747435182015-10-12T10:01:00.004-07:002015-10-12T10:01:43.244-07:00Polycarb hatch update<span style="font-family: Trebuchet MS, sans-serif; font-size: x-small;">Carefully painted a black band around the outer edge of the hatch:</span><br />
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<span style="font-family: Trebuchet MS, sans-serif; font-size: x-small;">I also added a 10mm self adhesive foam strip along the trailing edge of the roof panel. Then mocked up to the car again. </span></div>
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<span style="font-family: Trebuchet MS, sans-serif; font-size: x-small;">Really happy with how it has come out. Yes there are some small gaps, but with the nature of the way I've "cut and shut" the rear clam these are probably as small as I could have ever hoped to get them. For a track car it is certainly looking more than passable now! :-)</span></div>
Unknownnoreply@blogger.com0tag:blogger.com,1999:blog-1824501915430272363.post-43925319866280974852015-10-03T08:33:00.002-07:002015-10-03T08:33:22.274-07:00Cooling & engine systems test<span style="font-family: Trebuchet MS, sans-serif; font-size: x-small;"><br /></span>
<span style="font-family: Trebuchet MS, sans-serif; font-size: x-small;">Quite a wordy post this one, very unlike me! Anyway bear with.. ;)</span><br />
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<span style="font-family: Trebuchet MS, sans-serif; font-size: x-small;">So this morning I managed to bring the Pierburg EWP to life. Despite being designed for a PWM input signal it is possible to run it without. Simply apply 12V to Pin #1 and #2 and ground pin #4 and after a delay of around 5 seconds the pump will run at maximum output.</span><br />
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<span style="font-family: Trebuchet MS, sans-serif; font-size: x-small;">After sorting a minor leak on the block where I hadn't compressed an O-ring correctly, all seemed well and I topped up the system and ran it flat out for an hour, pausing occasionally to check the radiator top hose bleed nipple for any air.</span><br />
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<span style="font-family: Trebuchet MS, sans-serif; font-size: x-small;">The system took a total of 11.5 litres which is quite a lot more than I was expecting. None of the hose runs are excessive so the extra must be in the 56mm core radiator and the Ferrari block and heads.</span><br />
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<span style="font-family: Trebuchet MS, sans-serif; font-size: x-small;">For some comparisons on EWPs I found a very useful post from a chap with a bi-turbo Merc V12 engine on mbworld.org:</span><br />
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<i style="background-color: #f3f3f3;"><span style="color: #674ea7; font-family: Times, Times New Roman, serif;"><span style="font-size: 13.3333px;">Hi All, I've been getting interested in uprated IC pumps for my V12TT, and I've written a lonely mini-blog in the </span><a class="vglnk" href="http://rover.ebay.com/rover/13/0/19/DealFrame/DealFrame.cmp?bm=367&BEFID=96477&acode=379&code=379&aon=&crawler_id=507376&dealId=Qs5zPyP0aaKZiAbn5Ux9gA%3D%3D&searchID=&url=http%3A%2F%2Fautoplicity.com%2F2144615-weathertech-m275-exterior-miscellaneous%3Futm_source%3DShoppingCom%26utm_medium%3DCSE%26utm_campaign%3DShoppingComNOFITMENT&DealName=WeatherTech%20M275%20Exterior%20Miscellaneous&MerchantID=507376&HasLink=yes&category=0&AR=-1&NG=1&GR=1&ND=1&PN=1&RR=-1&ST=&MN=msnFeed&FPT=SDCF&NDS=1&NMS=1&NDP=1&MRS=&PD=0&brnId=2455&lnkId=8070676&Issdt=151002051520&IsFtr=0&IsSmart=0&dlprc=81.95&SKU=2144615" rel="nofollow" style="font-size: 13.3333px;" target="_blank">M275</a><span style="font-size: 13.3333px;"> </span><span style="font-size: 13.3333px;">V12 Bi-Turbo Platform forum for a while. I've been scooping up all the information I can find out about pumps, and put it in one place where each pump can be compared on a comparable basis. I've just added the Pierburg pumps to that comparison, and I thought anyone reading this thread might be interested - well, more than the </span><a class="vglnk" href="http://rover.ebay.com/rover/13/0/19/DealFrame/DealFrame.cmp?bm=367&BEFID=96477&acode=379&code=379&aon=&crawler_id=507376&dealId=Qs5zPyP0aaKZiAbn5Ux9gA%3D%3D&searchID=&url=http%3A%2F%2Fautoplicity.com%2F2144615-weathertech-m275-exterior-miscellaneous%3Futm_source%3DShoppingCom%26utm_medium%3DCSE%26utm_campaign%3DShoppingComNOFITMENT&DealName=WeatherTech%20M275%20Exterior%20Miscellaneous&MerchantID=507376&HasLink=yes&category=0&AR=-1&NG=1&GR=1&ND=1&PN=1&RR=-1&ST=&MN=msnFeed&FPT=SDCF&NDS=1&NMS=1&NDP=1&MRS=&PD=0&brnId=2455&lnkId=8070676&Issdt=151002051520&IsFtr=0&IsSmart=0&dlprc=81.95&SKU=2144615" rel="nofollow" style="font-size: 13.3333px;" target="_blank">M275</a><span style="font-size: 13.3333px;"> </span><span style="font-size: 13.3333px;">regulars, at any rate. This is what I just wrote over there: </span><br style="font-size: 13.3333px;" /><br style="font-size: 13.3333px;" /><a href="http://mbworld.org/forums/m275-v12-bi-turbo-platform/491594-understanding-intercooling-charge-coolers-heat-exchangers-circulation-pumps.html" style="font-size: 13.3333px;" target="_blank">Understanding Intercooling, Charge-Coolers, Heat Exchangers and Circulation Pumps</a><br style="font-size: 13.3333px;" /><br style="font-size: 13.3333px;" /><span style="font-size: 13.3333px;"></span><span style="font-size: 13.3333px;">These are probably best know as "The </span><span style="font-size: 13.3333px;">BMW pump",</span><span style="font-size: 13.3333px;"> </span><span style="font-size: 13.3333px;">but its actually a range of pumps for different applications. They range from the 15W WCP circulation pump (for heating and cooling when the engine is off) to a </span><a class="vglnk" href="http://click.linksynergy.com/link?id=je6NUbpObpQ&offerid=308596.269677&type=15&murl=http%3A%2F%2Ftracking.searchmarketing.com%2Fclick.asp%3Faid%3D730010170002210593&mid=3437" rel="nofollow" style="font-size: 13.3333px;" target="_blank">1100W</a><span style="font-size: 13.3333px;"> </span><span style="font-size: 13.3333px;">monster to replace the biggest mechanical pumps. An </span><a class="vglnk" href="http://www.cabelas.com/product/Intex-reg-Quick-Fill-AC-Electric-Pump/1168812.uts?productVariantId=3098573" rel="nofollow" style="font-size: 13.3333px;" target="_blank">electric pump</a><span style="font-size: 13.3333px;"> </span><span style="font-size: 13.3333px;">is still a bit of a novelty, but following BMW's lead, I think they're likely to become commonplace. There are probably four of interest: </span><br style="font-size: 13.3333px;" /><br style="font-size: 13.3333px;" /><span style="font-size: 13.3333px;">CWA 50 . Circulation pump, 50W , 6000 rpm, 24 lpm @ 0.60 bar</span><br style="font-size: 13.3333px;" /><span style="font-size: 13.3333px;">CWA 100 Circulation pump, 100W, 7200 rpm, 30 lpm @ 0.85 bar</span><br style="font-size: 13.3333px;" /><br style="font-size: 13.3333px;" /><span style="font-size: 13.3333px;">CWA 200 Coolant pump, 200W, 4500 rpm, 120 lpm @ 0.45 bar</span><br style="font-size: 13.3333px;" /><span style="font-size: 13.3333px;">CWA 400 Coolant pump, 400W, 10000 rpm, 150 lpm @ 0.80 bar</span><br style="font-size: 13.3333px;" /><br style="font-size: 13.3333px;" /><span style="font-size: 13.3333px;"></span><span style="font-size: 13.3333px;">The CWA 50 is used as a </span><a class="vglnk" href="http://viglink.pgpartner.com/rd.php?r=8395&m=889686052&q=n&rdgt=1443802270&it=1444234270&et=1444407070&priceret=5172.99&pg=~~3&k=44ab886ded1d4518fde35a179f71a37b&source=feed&url=http%3A%2F%2Fwww%2Eamericanmuscle%2Ecom%2Fvortech%2Dsc%2Dtuner%2Dblack%2D1114gt%2Ehtml%3Futm%5Fcontent%3Dvortech%2Dsc%2Dtuner%2Dblack%2D1114gt%26utm%5Fcampaign%3DPGNoFitmentV1%26utm%5Fsource%3DPGrabber%26utm%5Fmedium%3DShopping%26AMID%3Dvortech%2Dsc%2Dtuner%2Dblack%2D1114gt%2DNoFitment&st=feed&mt=~~~~~~~~n~~~" rel="nofollow" style="font-size: 13.3333px;" target="_blank">charge cooler</a><span style="font-size: 13.3333px;"> </span><span style="font-size: 13.3333px;">pump on the recent BMW V8TT engine, and the CWA 200 is used as the </span><span style="font-size: 13.3333px;">coolant</span><span style="font-size: 13.3333px;"> pump on a wide range of recent BM's. The circulation pumps have relatively low flow and high pressure, while the coolant pumps are obviously high flow. Like all good pumps, they're specified by their flow rate under pressure, so we know what their </span><span style="font-size: 13.3333px;">installed performance</span><span style="font-size: 13.3333px;"> </span><span style="font-size: 13.3333px;">is going to be. Contrast that with the </span><span style="font-size: 13.3333px;">Meziere WP136S</span><span style="font-size: 13.3333px;">, which simply claims 20 gpm/76 lpm open pipe. I don't have much information about how the WP136 performs in an IC system, so I used what I could find. Like the Meziere, the big Johnson and Davies Craig pumps also claim high open pipe flow, but when I put the Pierburgs onto my Flow Characteristics chart, an interesting picture emerges. </span><br style="font-size: 13.3333px;" /><br style="font-size: 13.3333px;" /><span style="font-size: 13.3333px;"></span><span style="font-size: 13.3333px;">For the purposes of charge cooling, these pumps rock. If you look at the </span><a class="vglnk" href="http://viglink.pgpartner.com/rd.php?r=8395&m=889686052&q=n&rdgt=1443802270&it=1444234270&et=1444407070&priceret=5172.99&pg=~~3&k=44ab886ded1d4518fde35a179f71a37b&source=feed&url=http%3A%2F%2Fwww%2Eamericanmuscle%2Ecom%2Fvortech%2Dsc%2Dtuner%2Dblack%2D1114gt%2Ehtml%3Futm%5Fcontent%3Dvortech%2Dsc%2Dtuner%2Dblack%2D1114gt%26utm%5Fcampaign%3DPGNoFitmentV1%26utm%5Fsource%3DPGrabber%26utm%5Fmedium%3DShopping%26AMID%3Dvortech%2Dsc%2Dtuner%2Dblack%2D1114gt%2DNoFitment&st=feed&mt=~~~~~~~~n~~~" rel="nofollow" style="font-size: 13.3333px;" target="_blank">Charge Cooler</a><span style="font-size: 13.3333px;"> </span><span style="font-size: 13.3333px;">Resistance curve, which gives an indication of the pressure/flow characteristics for a typically constricted </span><span style="font-size: 13.3333px;">charge cooler</span><span style="font-size: 13.3333px;"></span><span style="font-size: 13.3333px;">system, you can see which pumps will give good installed performance. The CWA 50 beats all-comers so far, and the 100 is better still, even achieving one bar pressure differential at low flow rates. For </span><span style="font-size: 13.3333px;">charge cooler</span><span style="font-size: 13.3333px;"> </span><span style="font-size: 13.3333px;">systems, these are two meaty pumps. I believe the CWA 100 is what Renntech use for their new IC pump, and it seems to be exactly what's needed. Shame about the silly price. </span><br style="font-size: 13.3333px;" /><br style="font-size: 13.3333px;" /><span style="font-size: 13.3333px;"></span><span style="font-size: 13.3333px;">The CWA 200 & 400 coolant pumps are off the chart, flowing over 100 lpm, and I didn't even try to plot them. They're huge, but you can see they meet different requirements. Where the 50 & 100 (like the Bosch pumps) fit the </span><a class="vglnk" href="http://viglink.pgpartner.com/rd.php?r=8395&m=889686052&q=n&rdgt=1443802270&it=1444234270&et=1444407070&priceret=5172.99&pg=~~3&k=44ab886ded1d4518fde35a179f71a37b&source=feed&url=http%3A%2F%2Fwww%2Eamericanmuscle%2Ecom%2Fvortech%2Dsc%2Dtuner%2Dblack%2D1114gt%2Ehtml%3Futm%5Fcontent%3Dvortech%2Dsc%2Dtuner%2Dblack%2D1114gt%26utm%5Fcampaign%3DPGNoFitmentV1%26utm%5Fsource%3DPGrabber%26utm%5Fmedium%3DShopping%26AMID%3Dvortech%2Dsc%2Dtuner%2Dblack%2D1114gt%2DNoFitment&st=feed&mt=~~~~~~~~n~~~" rel="nofollow" style="font-size: 13.3333px;" target="_blank">Charge Cooler</a><span style="font-size: 13.3333px;"> </span><span style="font-size: 13.3333px;">Resistance curve pretty well, the 200 & 400 are closer to the Engine Resistance characteristic. In fact, the Pierburg stats tend to back up what I've supposed are the installed characteristics for IC and </span><span style="font-size: 13.3333px;">engine cooling</span><span style="font-size: 13.3333px;">, with a big difference in the pressure/flow curves. If anything, I think the differences should be even greater, with an even steeper IC curve and a shallow coolant curve. </span><br style="font-size: 13.3333px;" /><br style="font-size: 13.3333px;" /><span style="font-size: 13.3333px;"></span><span style="font-size: 13.3333px;">The other thing that's interesting about the Pierburg pumps is that they facilitate </span><a class="vglnk" href="http://efaucets.com/detail.asp?Product_ID=72W&cm_mmc=portals-_-Commission%20Junction-_-product-_-72W" rel="nofollow" style="font-size: 13.3333px;" target="_blank">electronic variable speedcontrol</a><span style="font-size: 13.3333px;">. They can be slowed down almost to a stop, for fast warm-up and to save electrical power. In theory, they can control water flow well enough to avoid the need for a thermostat. That might not avoid</span><span style="font-size: 13.3333px;">hot spots</span><span style="font-size: 13.3333px;"> </span><span style="font-size: 13.3333px;">in the engine during warm-up, so I don't believe anybody has actually implemented that yet, but it sounds ideal for a </span><a class="vglnk" href="http://viglink.pgpartner.com/rd.php?r=8395&m=889686052&q=n&rdgt=1443802270&it=1444234270&et=1444407070&priceret=5172.99&pg=~~3&k=44ab886ded1d4518fde35a179f71a37b&source=feed&url=http%3A%2F%2Fwww%2Eamericanmuscle%2Ecom%2Fvortech%2Dsc%2Dtuner%2Dblack%2D1114gt%2Ehtml%3Futm%5Fcontent%3Dvortech%2Dsc%2Dtuner%2Dblack%2D1114gt%26utm%5Fcampaign%3DPGNoFitmentV1%26utm%5Fsource%3DPGrabber%26utm%5Fmedium%3DShopping%26AMID%3Dvortech%2Dsc%2Dtuner%2Dblack%2D1114gt%2DNoFitment&st=feed&mt=~~~~~~~~n~~~" rel="nofollow" style="font-size: 13.3333px;" target="_blank">charge cooler</a><span style="font-size: 13.3333px;">. </span></span></i><br />
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<a href="http://4.bp.blogspot.com/-FeJ4Nhrzu3Q/Vg_wUgOiO0I/AAAAAAAAA5M/D2Lfjxl2QFo/s1600/PumpCharacteristics130421-page-2_zps9500e15f.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="452" src="http://4.bp.blogspot.com/-FeJ4Nhrzu3Q/Vg_wUgOiO0I/AAAAAAAAA5M/D2Lfjxl2QFo/s640/PumpCharacteristics130421-page-2_zps9500e15f.jpg" width="640" /></a></div>
<span style="background-color: white;"><span style="font-family: Trebuchet MS, sans-serif; font-size: x-small;">So the CWA200 I have is off the scale on this chart, flowing ~115 l/min @ 0.45bar.</span></span><br />
<span style="background-color: white;"><span style="font-family: Trebuchet MS, sans-serif; font-size: x-small;"><br /></span></span>
<span style="background-color: white;"><span style="font-family: Trebuchet MS, sans-serif; font-size: x-small;">With the large rad, pump potential, and large air-to-oil cooler mounted on the splitter it is highly conceivable that I will be able to overcool the engine despite the large capacity and high rev limit. It that happens I can turn down the pump speed slightly, and potentially block off some airflow to the oil cooler.</span></span><br />
<span style="background-color: white;"><span style="font-family: Trebuchet MS, sans-serif; font-size: x-small;"><br /></span></span>
<span style="background-color: white;"><span style="font-family: Trebuchet MS, sans-serif; font-size: x-small;"><br /></span></span>
<span style="background-color: white;"><span style="font-family: Trebuchet MS, sans-serif; font-size: x-small;"><u>Engine systems:</u></span></span><br />
<span style="background-color: white;"><span style="font-family: Trebuchet MS, sans-serif; font-size: x-small;"><br /></span></span>
<span style="background-color: white;"><span style="font-family: Trebuchet MS, sans-serif; font-size: x-small;">So I have now tested coolant circuit flat out for an hour @whatever pressure my system creates, tested fuel pump flat out for an hour @ 3.5bar, and tested the dry sump oil circuit flows during cold cranking of the engine!</span></span><br />
<span style="background-color: white;"><span style="font-family: Trebuchet MS, sans-serif; font-size: x-small;"><br /></span></span>
<span style="background-color: white;"><span style="font-family: Trebuchet MS, sans-serif; font-size: x-small;">This is really all the 'due diligence' I can do without a running engine to generate proper temperature and vibration, but I still count it as valuable. I picked up on both a minor fuel and coolant leak during the testing, (which is the point of testing) and much better to find these things now as opposed to during the first rolling road day or shakedown drive...</span></span><br />
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<br />Unknownnoreply@blogger.com0tag:blogger.com,1999:blog-1824501915430272363.post-72604047317146472552015-10-01T10:43:00.001-07:002015-10-01T10:43:27.064-07:00Switches & Wind Deflectors<span style="font-family: Trebuchet MS, sans-serif; font-size: x-small;"><br /></span>
<span style="font-family: Trebuchet MS, sans-serif; font-size: x-small;">After much strife I eventually got the new switches working successfully.</span><br />
<span style="font-family: Trebuchet MS, sans-serif; font-size: x-small;"><br /></span>
<span style="font-family: Trebuchet MS, sans-serif; font-size: x-small;">From left to right:</span><br />
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<span style="font-family: Trebuchet MS, sans-serif; font-size: x-small;">1) Hazard, 2) Master Lamps On, 3) Screen Demist, 4) Front DRLs, 5) Rear Rain/Fog</span><br />
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<a href="http://3.bp.blogspot.com/-1R1Mvm2lXz8/Vg1vgaFGS-I/AAAAAAAAA4g/hnXsR4dJuak/s1600/DSC_0690%257E2.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><span style="font-family: Trebuchet MS, sans-serif; font-size: x-small;"><img border="0" height="320" src="http://3.bp.blogspot.com/-1R1Mvm2lXz8/Vg1vgaFGS-I/AAAAAAAAA4g/hnXsR4dJuak/s320/DSC_0690%257E2.jpg" width="181" /></span></a></div>
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<a href="http://3.bp.blogspot.com/-whZAWX9N0Yw/Vg1vjHtfeoI/AAAAAAAAA4s/AU3ahRNS26Y/s1600/DSCF2915%257E2.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><span style="font-family: Trebuchet MS, sans-serif; font-size: x-small;"><img border="0" height="249" src="http://3.bp.blogspot.com/-whZAWX9N0Yw/Vg1vjHtfeoI/AAAAAAAAA4s/AU3ahRNS26Y/s320/DSCF2915%257E2.jpg" width="320" /></span></a></div>
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<a href="http://2.bp.blogspot.com/-r84yzKiTH8s/Vg1vjHT7b9I/AAAAAAAAA4o/GhEhoKLQQb8/s1600/DSCF2918%257E2.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><span style="font-family: Trebuchet MS, sans-serif; font-size: x-small;"><img border="0" height="232" src="http://2.bp.blogspot.com/-r84yzKiTH8s/Vg1vjHT7b9I/AAAAAAAAA4o/GhEhoKLQQb8/s320/DSCF2918%257E2.jpg" width="320" /></span></a></div>
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<span style="font-family: Trebuchet MS, sans-serif; font-size: x-small;">Very happy with how they came out :)</span><br />
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<span style="font-family: Trebuchet MS, sans-serif; font-size: x-small;">Another area I have been metaphorically losing sleep over is the seal between top of window and roof. With the correct S1 seals no longer available from Lotus, or fetching silly money it was down to making something myself. </span><br />
<span style="font-family: Trebuchet MS, sans-serif; font-size: x-small;"><br /></span>
<span style="font-family: Trebuchet MS, sans-serif; font-size: x-small;">I messed around with some D-section foam for ages, but couldn't come up with something I was happy with. So I changed tack and decided to try a wind deflector solution instead. I cut down some wind deflectors from a Megane Coupe and managed to get them fitting nicely with a tight gap to the top of the window as the door closes. </span><br />
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<a href="http://1.bp.blogspot.com/-I1tuBoiVVhQ/Vg1v2qJL1pI/AAAAAAAAA44/Q8N1B_wrmWo/s1600/DSCF2922%257E2%257E2.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><span style="font-family: Trebuchet MS, sans-serif; font-size: x-small;"><img border="0" height="240" src="http://1.bp.blogspot.com/-I1tuBoiVVhQ/Vg1v2qJL1pI/AAAAAAAAA44/Q8N1B_wrmWo/s320/DSCF2922%257E2%257E2.jpg" width="320" /></span></a></div>
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<span style="font-family: Trebuchet MS, sans-serif; font-size: x-small;"><br /></span>
<span style="font-family: Trebuchet MS, sans-serif; font-size: x-small;">As the car won't really be used in wet weather this should be sufficient to keep any mild drizzle mostly out of the cockpit!</span>Unknownnoreply@blogger.com0tag:blogger.com,1999:blog-1824501915430272363.post-86585108863971251412015-09-22T10:49:00.002-07:002015-09-22T10:49:47.063-07:00Polycarbonate Engine Hatch<span style="font-family: Trebuchet MS, sans-serif; font-size: x-small;">Over the past 4 months or so I have had a bit of a side project on the car. This has involved working with a acrylics company in order to tool up an affordable, lightweight clear polycarbonate engine hatch option for the S1 Exige.</span><br />
<span style="font-family: Trebuchet MS, sans-serif; font-size: x-small;"><br /></span>
<span style="font-family: Trebuchet MS, sans-serif; font-size: x-small;">Finally after much development I have the first part on my car. Weighing in at about 5.5kg, it's a good 3-4kg lighter than the OEM part!</span><br />
<span style="font-family: Trebuchet MS, sans-serif; font-size: x-small;"><br /></span>
<span style="font-family: Trebuchet MS, sans-serif; font-size: x-small;">I am able to offer these in a rough-trimmed state for the user to trim and fit themselves as of now. Contact me on here or SELOC for details. In the future I hope to offer a fitting solution that looks totally "Factory Fit".</span><br />
<span style="font-family: Trebuchet MS, sans-serif; font-size: x-small;"><br /></span>
<span style="font-family: Trebuchet MS, sans-serif; font-size: x-small;">Still waiting for some catches to arrive before I can finalise the fitting of it, but it's pretty close now I have finished trimming it:</span><br />
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<a href="http://1.bp.blogspot.com/-KktVxgIWWP4/VgGSw28WMnI/AAAAAAAAA3E/EhqK_aJk5GM/s1600/DSCF2892%257E2%257E2.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><span style="font-family: Trebuchet MS, sans-serif; font-size: x-small;"><img border="0" height="267" src="http://1.bp.blogspot.com/-KktVxgIWWP4/VgGSw28WMnI/AAAAAAAAA3E/EhqK_aJk5GM/s400/DSCF2892%257E2%257E2.jpg" width="400" /></span></a></div>
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<span style="font-family: Trebuchet MS, sans-serif; font-size: x-small;">prior to trimming with about 15-20mm stock on all around</span></div>
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<a href="http://3.bp.blogspot.com/-HbThOluNF1A/VgGSwP6Y5UI/AAAAAAAAA3A/FF_hegUMqy8/s1600/DSCF2897%257E2.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="308" src="http://3.bp.blogspot.com/-HbThOluNF1A/VgGSwP6Y5UI/AAAAAAAAA3A/FF_hegUMqy8/s400/DSCF2897%257E2.jpg" width="400" /></a></div>
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<br />Unknownnoreply@blogger.com0tag:blogger.com,1999:blog-1824501915430272363.post-62975852704973390762015-09-19T12:34:00.001-07:002015-09-19T12:34:59.211-07:00screen demist<span style="font-family: Trebuchet MS, sans-serif; font-size: x-small;">As I removed the heater matrix and fan in the interest of weight saving I was left with no method of screen demist.</span><br />
<span style="font-family: Trebuchet MS, sans-serif; font-size: x-small;"><br /></span>
<span style="font-family: Trebuchet MS, sans-serif; font-size: x-small;">One option would be the heated screens that are available, however they are expensive to replace following stonechip damage and also they have quite a high current draw, not good when you only have a tiny alternator!</span><br />
<span style="font-family: Trebuchet MS, sans-serif; font-size: x-small;"><br /></span>
<span style="font-family: Trebuchet MS, sans-serif; font-size: x-small;">So the solution I have come up with is to run 4 small fans in the vents in the dashboard, on a manual switch so I can blow some air over the screen on demand. Total current draw = 0.6Amps</span><br />
<span style="font-family: Trebuchet MS, sans-serif; font-size: x-small;"><br /></span>
<span style="font-family: Trebuchet MS, sans-serif; font-size: x-small;">As always, pictures explain better than I can:</span><br />
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<br />Unknownnoreply@blogger.com0tag:blogger.com,1999:blog-1824501915430272363.post-42918540609701038852015-09-17T13:17:00.003-07:002015-09-17T13:17:47.907-07:00mocking up diffuser<span style="font-family: Trebuchet MS, sans-serif; font-size: x-small;">Playing around with the standard S1 diffuser. Still quite a lot to do on this as I need to extend it quite a bit to make it in keeping with the rest of the bodywork. </span><br />
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<span style="font-family: Trebuchet MS, sans-serif; font-size: x-small;">Looking good potential though :) </span><br />
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<span style="font-family: Trebuchet MS, sans-serif; font-size: x-small;">(got the decent camera out for change rather than being lazy and using my phone)</span><br />
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<a href="http://2.bp.blogspot.com/-CsiYX-HEZn4/Vfr9dWRWt5I/AAAAAAAAA14/u3U7kKHxFkE/s1600/DSCF2549%257E2.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="434" src="http://2.bp.blogspot.com/-CsiYX-HEZn4/Vfr9dWRWt5I/AAAAAAAAA14/u3U7kKHxFkE/s640/DSCF2549%257E2.jpg" width="640" /></a></div>
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<br />Unknownnoreply@blogger.com0tag:blogger.com,1999:blog-1824501915430272363.post-3376991602030888252015-09-12T14:44:00.005-07:002015-09-12T14:44:59.510-07:00misc. updates<div class="separator" style="clear: both; text-align: center;">
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<span style="font-family: Trebuchet MS, sans-serif; font-size: x-small;">Once again I've been a bit slack at keeping the blog upto date. Progress has been good though, I'll let the pictures do the talking.</span></div>
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<a href="http://4.bp.blogspot.com/-X9F_CXz2_X0/VfSa9jK9s0I/AAAAAAAAA0s/hG9iBayl7Gs/s1600/DSC_0605.JPG" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><span style="font-family: Trebuchet MS, sans-serif; font-size: x-small;"><img border="0" height="225" src="http://4.bp.blogspot.com/-X9F_CXz2_X0/VfSa9jK9s0I/AAAAAAAAA0s/hG9iBayl7Gs/s400/DSC_0605.JPG" width="400" /></span></a></div>
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<span style="font-family: 'Trebuchet MS', sans-serif; font-size: x-small;">Splitter removed for paint.</span></div>
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<a href="http://1.bp.blogspot.com/-9svXHeoU8nc/VfSa9GM5exI/AAAAAAAAA0k/JG-TzIr8zAM/s1600/DSC_0606.JPG" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><span style="font-family: Trebuchet MS, sans-serif; font-size: x-small;"><img border="0" height="225" src="http://1.bp.blogspot.com/-9svXHeoU8nc/VfSa9GM5exI/AAAAAAAAA0k/JG-TzIr8zAM/s400/DSC_0606.JPG" width="400" /></span></a></div>
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<span style="font-family: Trebuchet MS, sans-serif; font-size: x-small;">Battery tray.</span></div>
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<a href="http://1.bp.blogspot.com/-6ur14UvfLyk/VfSa9chtdAI/AAAAAAAAA0o/Zqz1lKbhVT4/s1600/DSC_0607.JPG" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><span style="font-family: Trebuchet MS, sans-serif; font-size: x-small;"><img border="0" height="180" src="http://1.bp.blogspot.com/-6ur14UvfLyk/VfSa9chtdAI/AAAAAAAAA0o/Zqz1lKbhVT4/s320/DSC_0607.JPG" width="320" /></span></a></div>
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<span style="font-family: Trebuchet MS, sans-serif; font-size: x-small;">Inserts (to prevent fasteners pulling though/wearing out)</span></div>
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<a href="http://3.bp.blogspot.com/-hIwcHFBqDLk/VfSa_QlWO-I/AAAAAAAAA08/pAcc_0T9_dA/s1600/DSC_0613.JPG" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><span style="font-family: Trebuchet MS, sans-serif; font-size: x-small;"><img border="0" height="180" src="http://3.bp.blogspot.com/-hIwcHFBqDLk/VfSa_QlWO-I/AAAAAAAAA08/pAcc_0T9_dA/s320/DSC_0613.JPG" width="320" /></span></a></div>
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<span style="font-family: Trebuchet MS, sans-serif; font-size: x-small;">Splitter back on the car.</span></div>
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<a href="http://4.bp.blogspot.com/-VzYS3MloXWY/VfSbAVV9nxI/AAAAAAAAA1M/MGwvbnG8XFg/s1600/DSC_0614.JPG" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><span style="font-family: Trebuchet MS, sans-serif; font-size: x-small;"><img border="0" height="180" src="http://4.bp.blogspot.com/-VzYS3MloXWY/VfSbAVV9nxI/AAAAAAAAA1M/MGwvbnG8XFg/s320/DSC_0614.JPG" width="320" /></span></a></div>
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<span style="font-family: Trebuchet MS, sans-serif; font-size: x-small;">Battery pack mounted to splitter for best weight distribution.</span></div>
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<a href="http://4.bp.blogspot.com/-4D70_BSVTZs/VfSa_15oBxI/AAAAAAAAA1A/0o3pO2Fa8h0/s1600/DSC_0620%257E2.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><span style="font-family: Trebuchet MS, sans-serif; font-size: x-small;"><img border="0" height="230" src="http://4.bp.blogspot.com/-4D70_BSVTZs/VfSa_15oBxI/AAAAAAAAA1A/0o3pO2Fa8h0/s320/DSC_0620%257E2.jpg" width="320" /></span></a></div>
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<span style="font-family: Trebuchet MS, sans-serif; font-size: x-small;">Front wheels roughly mocked up (I still don't have the front uprights)</span></div>
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<a href="http://2.bp.blogspot.com/-cnD3_PA2jjY/VfSbAyqwWRI/AAAAAAAAA1Q/HgO7oMqNc5Y/s1600/DSC_0653%257E2.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><span style="font-family: Trebuchet MS, sans-serif; font-size: x-small;"><img border="0" height="163" src="http://2.bp.blogspot.com/-cnD3_PA2jjY/VfSbAyqwWRI/AAAAAAAAA1Q/HgO7oMqNc5Y/s320/DSC_0653%257E2.jpg" width="320" /></span></a></div>
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<span style="font-family: Trebuchet MS, sans-serif; font-size: x-small;"> Radiator exit ducting.</span></div>
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<a href="http://4.bp.blogspot.com/-PTveSOOVUXQ/VfSbBYiFvsI/AAAAAAAAA1Y/lvAizdmgprM/s1600/DSC_0654%257E2.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><span style="font-family: Trebuchet MS, sans-serif; font-size: x-small;"><img border="0" height="182" src="http://4.bp.blogspot.com/-PTveSOOVUXQ/VfSbBYiFvsI/AAAAAAAAA1Y/lvAizdmgprM/s320/DSC_0654%257E2.jpg" width="320" /></span></a></div>
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<span style="font-family: Trebuchet MS, sans-serif; font-size: x-small;">Trying to ensure no air can bypass the rad at all. Working in 0.5mm aluminium so it is nice and conformable.</span></div>
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<span style="font-family: Trebuchet MS, sans-serif; font-size: x-small;">NTR shocks are now cleaned up and fitted to the car :-)</span></div>
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more soon!</div>
Unknownnoreply@blogger.com0tag:blogger.com,1999:blog-1824501915430272363.post-41456118512681898032015-08-30T05:12:00.004-07:002015-08-30T05:12:47.611-07:00cranking test!<br />
<span style="font-family: Trebuchet MS, sans-serif; font-size: x-small;">Quite a nice milestone this one. Had a couple of hours spare this morning so rigged up a battery direct to the starter motor, as I hadn't actually tested the motor and solenoid which came with the 2nd hand (but only 19,000mile) gearbox. </span><br />
<span style="font-family: Trebuchet MS, sans-serif; font-size: x-small;"><br /></span>
<span style="font-family: Trebuchet MS, sans-serif; font-size: x-small;">Cranking the engine over allowed me to visually check that the alternator mounting looked ok. It looked fine, but the real test of my pulley will be once the engine is running at full speed.</span><br />
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<span style="font-family: Trebuchet MS, sans-serif; font-size: x-small;">The cranking test also enabled me to check my oil circuit. The pump seems to be priming correctly and even at this slow speed cranking I was getting good oil flow around the circuit and back into the dry sump tank. </span><span style="font-family: Wingdings;">J</span><br />
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<a href="http://1.bp.blogspot.com/-bBg7qO8lTHg/VeLxnO8YQdI/AAAAAAAAAyo/qQHs6HOoXjw/s1600/cranking.png" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="179" src="http://1.bp.blogspot.com/-bBg7qO8lTHg/VeLxnO8YQdI/AAAAAAAAAyo/qQHs6HOoXjw/s320/cranking.png" width="320" /></a></div>
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<span style="font-family: Trebuchet MS, sans-serif; font-size: x-small;">Worth mentioning: the cranking is such slow speed as I am using a knackered old battery from my road car for the testing. It still holds charge but drops down pretty quickly under load. You can just about see in the image from above, the multimeter reads 14.2V, under cranking this was dropping down to 10.5V or so after just a couple of seconds. I will actually be running two batteries in parallel on the Exige as I have figured out this is the lightest way to achieve the CCA (cold cranking amps) I think I'll need for this large, high compression V8.</span><br />
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<span style="font-family: Trebuchet MS, sans-serif; font-size: x-small;">Quick vid of the alternator pulley during cranking:</span><br />
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<iframe allowfullscreen='allowfullscreen' webkitallowfullscreen='webkitallowfullscreen' mozallowfullscreen='mozallowfullscreen' width='320' height='266' src='https://www.blogger.com/video.g?token=AD6v5dwsGpfC5t7qIMWhPFHbjaRRUsftjKH-6iwX4QwN6D48McXm8pO7pI1p1KLUXiiG-hz7Q_ub9NSg4JdbxmZZ8A' class='b-hbp-video b-uploaded' frameborder='0'></iframe></div>
<br />Unknownnoreply@blogger.com0tag:blogger.com,1999:blog-1824501915430272363.post-57880405663131929762015-08-24T13:07:00.004-07:002016-01-01T05:42:47.444-08:00chassis loom complete<div class="separator" style="clear: both; text-align: center;">
<span style="font-family: Trebuchet MS, sans-serif; font-size: x-small;">Hazards:</span></div>
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<span style="font-family: Trebuchet MS, sans-serif; font-size: x-small;">Wiper:</span></div>
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<span style="font-family: Trebuchet MS, sans-serif; font-size: x-small;">This completes the chassis loom. I have now tested and confirmed as working:</span></div>
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<li style="text-align: justify;"><span style="font-family: Trebuchet MS, sans-serif; font-size: x-small;">LED indicators (LED friendly relay in-transit to slow the flash speed above)</span></li>
<li style="text-align: justify;"><span style="font-family: Trebuchet MS, sans-serif; font-size: x-small;">LED headlights</span></li>
<li style="text-align: justify;"><span style="font-family: Trebuchet MS, sans-serif; font-size: x-small;">LED brake lights</span></li>
<li style="text-align: justify;"><span style="font-family: Trebuchet MS, sans-serif; font-size: x-small;">LED rear rain light</span></li>
<li style="text-align: justify;"><span style="font-family: Trebuchet MS, sans-serif; font-size: x-small;">new washer pump</span></li>
<li style="text-align: justify;"><span style="font-family: Trebuchet MS, sans-serif; font-size: x-small;">new horn with new horn button</span></li>
<li style="text-align: justify;"><span style="font-family: Trebuchet MS, sans-serif; font-size: x-small;">wiper with 3 speeds as per standard but with vertical park</span></li>
<li style="text-align: justify;"><span style="font-family: Trebuchet MS, sans-serif; font-size: x-small;">Fuel pump</span></li>
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<span style="font-family: Trebuchet MS, sans-serif; font-size: x-small;">All this with removing a total of over 2kgs from the standard loom! Not to mention tarting up the horrible standard switches with some nicer illuminated toggle items.</span></div>
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<span style="font-family: Trebuchet MS, sans-serif; font-size: x-small;">There is one further addition I plan to make to the chassis loom and that is to add some small laptop fans to act as screen demist now that I have removed the standard heater matrix and fan.</span><br />
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<span style="font-family: Trebuchet MS, sans-serif; font-size: x-small;">In other news, the main loom design is complete. Further updates shortly but here is the schematic:</span><br />
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<a href="http://2.bp.blogspot.com/-vsL3aszPywg/VoaCF86bK2I/AAAAAAAABBI/AY0T7YOjXU4/s1600/wiring%2Bloom%2Bdrawing%2Bvers4.PNG" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="320" src="http://2.bp.blogspot.com/-vsL3aszPywg/VoaCF86bK2I/AAAAAAAABBI/AY0T7YOjXU4/s320/wiring%2Bloom%2Bdrawing%2Bvers4.PNG" width="240" /></a></div>
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<br />Unknownnoreply@blogger.com0tag:blogger.com,1999:blog-1824501915430272363.post-33875315489830038602015-08-21T11:36:00.001-07:002015-08-21T11:36:52.419-07:00Electrical systems testing<div class="separator" style="clear: both; text-align: justify;">
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<span style="font-family: Trebuchet MS, sans-serif; font-size: x-small;">Sorry the updates have been a little lax lately. I have been busy on the car however so I'll try to cover quite a bit in this post.</span></div>
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<span style="font-family: Trebuchet MS, sans-serif; font-size: x-small;">The main focus has been on various aspects of the electrical system. I have been busy trying to get the lighting system working again having ripped out 75% of the standard loom. As this included the standard dash and also the alarm/immobiliser units the indicator hazard circuits were interrupted, and as yet I haven't managed to get them fixed.</span></div>
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<span style="font-family: Trebuchet MS, sans-serif; font-size: x-small;">The brake lights are fixed and working though:</span></div>
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<a href="http://4.bp.blogspot.com/-3ATudsMcRpg/VddtZdQyecI/AAAAAAAAAyA/HS5MXZxWK3w/s1600/DSC_0596.JPG" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="180" src="http://4.bp.blogspot.com/-3ATudsMcRpg/VddtZdQyecI/AAAAAAAAAyA/HS5MXZxWK3w/s320/DSC_0596.JPG" width="320" /></a></div>
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<span style="font-family: Trebuchet MS, sans-serif; font-size: x-small;">(as is the rear rain/fog light!)</span></div>
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<span style="font-family: Trebuchet MS, sans-serif; font-size: x-small;">The car is now full of fluids. Engine oil, gearbox oil, coolant and 10L of unleaded have been poured in. </span></div>
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<span style="font-family: Trebuchet MS, sans-serif; font-size: x-small;">Filling the coolant and fuel systems allows me to test the pumps. I started with the fuel system. Giving the fuel pump 12V allowed me to set the adjustable FPR (3.6bar) and check the system for leaks well prior to the first engine start:</span></div>
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<span style="font-family: 'Trebuchet MS', sans-serif; font-size: x-small;">The tissue paper around the unions is good trick to check for leaks. Sometimes a tiny leak is very heard to spot with the naked eye, and such a small amount of leaking petrol will quickly evaporate. So wrap some tissue paper around any unions you are suspicious of and then inspect. Even the tiniest leak will leave a mark. </span></div>
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So far the integrity of the system looks good. I am going to run an extended test for an hour or two later in the weekend just to be 100% sure.</div>
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Following completion of the fuel circuit testing I will be switching to the EWP. Even without the engine loom and PWM signal I can give the EWP 12V to kick it into action and check the coolant system for leaks.</div>
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<br />Unknownnoreply@blogger.com0tag:blogger.com,1999:blog-1824501915430272363.post-62319133793756500992015-08-16T12:22:00.000-07:002015-08-16T12:22:38.773-07:00Nitron NTR40<div class="separator" style="clear: both; text-align: center;">
<span style="font-family: Trebuchet MS, sans-serif; font-size: x-small;">Another nice set of bits has arrived. Nitron shocks with Eibach springs and helper springs.</span></div>
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<span style="font-family: Trebuchet MS, sans-serif; font-size: x-small;">These save 1.82 Kg in total over the standard Koni S1 shocks and springs!</span></div>
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<span style="font-family: Trebuchet MS, sans-serif; font-size: x-small;">I should be able to get these fitted in the next couple of days, starting with the rears.</span></div>
Unknownnoreply@blogger.com0tag:blogger.com,1999:blog-1824501915430272363.post-53246882681468001062015-07-31T10:35:00.002-07:002015-07-31T10:43:07.249-07:00wheels<span style="font-family: Trebuchet MS, sans-serif; font-size: x-small;">Apologies for the lack of updates, I had my wedding and honeymoon to attend to!</span><br />
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<span style="font-family: Trebuchet MS, sans-serif; font-size: x-small;">before I went away the wheels arrived and I mocked them up onto the car:</span><br />
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<a href="http://1.bp.blogspot.com/-tg-jXh9GF5U/VbuziI4MCgI/AAAAAAAAAwQ/i636aKCBjaA/s1600/DSC_0482%257E2.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="320" src="http://1.bp.blogspot.com/-tg-jXh9GF5U/VbuziI4MCgI/AAAAAAAAAwQ/i636aKCBjaA/s320/DSC_0482%257E2.jpg" width="197" /></a></div>
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<a href="http://2.bp.blogspot.com/-3xvQp4rbzAA/VbuzivhyoiI/AAAAAAAAAwU/Zri0Mi11dVs/s1600/DSC_0483%257E2.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="320" src="http://2.bp.blogspot.com/-3xvQp4rbzAA/VbuzivhyoiI/AAAAAAAAAwU/Zri0Mi11dVs/s320/DSC_0483%257E2.jpg" width="178" /></a></div>
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<a href="http://3.bp.blogspot.com/-P37h9nGy_KU/VbuzicBPDzI/AAAAAAAAAwY/ecKWxS7LpVQ/s1600/DSC_0485%257E2.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="180" src="http://3.bp.blogspot.com/-P37h9nGy_KU/VbuzicBPDzI/AAAAAAAAAwY/ecKWxS7LpVQ/s320/DSC_0485%257E2.jpg" width="320" /></a></div>
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<span style="font-family: Trebuchet MS, sans-serif; font-size: x-small;"><br /></span><span style="font-family: Trebuchet MS, sans-serif; font-size: x-small;">They didn't come in black so I had them re-done as soon as I got home again. This morning I picked up the wheels from the powdercoaters and got the front tyres fitted:</span><br />
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<span style="font-family: Trebuchet MS, sans-serif; font-size: x-small;">(tyres are Kumho V70As)</span></div>
Unknownnoreply@blogger.com0