Northern turbo build.

[sheffjohn]

Fell out with the build thread due to all my picture links failing.
But I've actually been busy working on it !

So here's a picture of where I stand currently.



Note, Seat not mounted.
Instruments and cowl not mounted.

[sheffjohn]

Finished mounting and mocking up my extra IVA setup for rear lights.

These were originally due to be removed after iva, but I actually like how they look ! So we will see.





The pipe is thick wall, so enough material to tap a thread into. Tapped an m10 thread to mount the rubberised motorbike indicators into.

Wiring for the stop/tail and indicators will run down the tube and tuck under the fuel tank cover from underneath the shock mounting plates.

[sheffjohn]

As seen in the pics above. It now also has some suspension fitted.

Picked up some second hand GAZ coilovers, uses gaz before and I like the fact they are rebuildable and repairable in the UK by the supplier.

So anything needed in the future shouldn't be too hard to get, or involve buying a full set of replacements.

[sheffjohn]

Wasn't looking forward to this job !
Eyeballed up one side to where I liked the look of, then took measurements and templates to make sure the opposite side matches.

Tip to anyone, double check where the catch pin will come out on the underside.

I VERY nearly put the catch an inch of further forward and it would have made the bracket underneath that holds the pin, much more awkward.

I realised my mistake and moved it backwards. Now the pin comes through close to a main frame bar that I have welded some brackets onto. These hold the aerocatch pins nice and snug to the edge of the engine bay and don't intrude.

[sheffjohn]

TUESDAY PRO TIP.





For god's sake, if your making your own manifold, and happen to be using an external wastegate, for fu**s sake cut the hole you need before you get the rest of the manifold welded up.

Using a holesaw to cut through a merge of 4 pipes, all thick wall stainless steel, when fully welded, is not easy or fun.

Big error on my part, but now fixed, just took ages with a holesaw and carbide burr !




Took a while to cut and shape the pipe to fit in the merge collector, but lad who does my welding is happy the fitment is good enough.

[sheffjohn]

Continuing the theme of starting more jobs and not totally finishing the previous ...
There is method in this though, I think getting more components onto the frame will help the overall build design, and not finishing bits off will leave room for wiring and changes I need to make.
Hopefully it will stop me having to RE-do tasks.

Cluster/gauge pod mounting.

Decided to make a flat plate. Roughly (for now) shaped to the bottom of the cowl. It has a 15mm ish lip bent 90degrees at the front which mounts to the gauge pod by nut and bolt (may become rivnut).








This plate is trapped between the steering column, and mounting bracket on the Exocet frame. It has two holes drilled in which the 2 column bolts locate through.



Side view shows the gap left. I'm leaving it like this till wiring is in. After that. Ill either fold the sides up to meet the bottom of the cowl, or I will make a fillet piece which fills the gap.
Unsure of the best way at the moment so will leave it for now.



The cowl cover rested on. The design of the cowl fits pretty snug around the front edge of the gauges, so mounting the rear of the cowl to the frame makes it really sturdy !

Little steel 90degree-ish bracket welded to the column mounting plate, and drilled and rivnutted.

Depending on how I tackle the sides of the big lower plate/cowl, I may also make a mounting point on each side which would hold the cowl to the lower plate.
I don't really think it's necessary but will see how it feels with added wiring weight etc. Rattling around behind the gauges.

[sheffjohn]

Couple of small updates.
Wheel selection. 15X8 ET0 ultralite Ul48. Pretty lightweight. Second hand but never fitted to a car so paid decent price for them.



[url=https://postimg.org/image/juke

Last picture in its old home. Finally found a unit closer to home, so had to make the car roll faster than intended so it could be moved.

[sheffjohn]

New home ! Nice and clean Compared to the last place it lived. Works pretty well time wise as I think I've done a lot of the mucky work. Hopefully the red floor will stay that way for a while.



Moving day ! Thankfully no rain so no worries about covering things up for transport.



Last pic shows reverse and fog. Ring led items. Fog is f1 and e marked so hopefully legal for iva.
Both mounted to a small bracket which I have welded to the rear bar. 2 X rivnuts. Hopefully it doesn't all fall off on the way back from the iva...

[Stiggy]

Looking good Sir, well done!
The inner pair of stop/ tail will not pass IVA as they are too far in. 400 mm min from edge of footprint to edge of light emitting area, this applies to all lights so if the inner pair are fitted they need to comply. You cannot just disconnect them for the test.
The fog and reverse may get noticed as being too close to the exhaust which I assume is coming out below later.

[sheffjohn]

Oct 22, 2017 17:14:18 GMT Stiggy said:

Looking good Sir, well done!
The inner pair of stop/ tail will not pass IVA as they are too far in. 400 mm min from edge of footprint to edge of light emitting area, this applies to all lights so if the inner pair are fitted they need to comply. You cannot just disconnect them for the test.
The fog and reverse may get noticed as being too close to the exhaust which I assume is coming out below later.

Cheers for the Input !

I'm unsure if I'm reading the table in my iva printout correctly in that case.

Underneath the 'stop lamps' section, is 'stop lamps (optional)'.

Whilst stop lamps have the 400mm outside measurement and height restrictions etc, the optional section says "n/a" for Max height, min height is the same as the mandatory stop lights, and against Max distance from side it says "if 2 are fitted, no requirement".

The way I read all that was that the inner lights (if I disconnect the sidelight function of them for the iva) would be classed as optional stop lamps and thus don't need to meet the position requirements.

I'm absolutely happy to be wrong though and I'll make adjustments if needs be. Said adjustment could be just remove the inner lamps for the iva maybe.



R.e. the exhaust, I hadn't considered the distance between lamps and exhaust as an iva issue. Ill consider moving the lamps when I build the exhaust.

Thanks a lot !

[sheffjohn]

Test fit (feel good picture) of the wheels. 15X8 et0, 205/50r15 tyre.

[sheffjohn]

Todays project was a cops conversion plate. Decided to move to individual coils instead of the original setup.

Reasons, strong spark to go with turbo conversion. Gets rid of old expensive mx5 coil. Frees up space behind cylinder head, no ugly ignition leads.
Work had an extra special staff sale on, so paid tuppence for some decent brand Toyota coils.

Made a plate. 3mm alloy strip, 40mm wide. 32mm holesaw for the plug holes. 4 m6 rivnuts in the plate pointing upwards gives me the 4 mounting points for the coils.

Will sort wiring out next week. I'm also going from normal injectors to Bosch 550cc ev14s (which if anyone needs I can get at VERY good prices,) these need different wiring plugs.

Ill make a loom for the injectors and coilpacks, which will replace the removable part of the Mx5 loom which feeds coils, injectors, temp sensor, and I think an earth point aswell.

The wiring which feeds that loom is cable tied to the rear engine lifting eye in my picture. Ill cut the loom there ish and put a new connector on.

[sheffjohn]

Happy New Year all !
Festive days off work gave me a bit of time for achieving.

Next task was/is cycle wings.

Started on the rear, figured they were easier as I hadn't found out front wheel bearings pull off by hand at this point !

Drilled and tapped the knuckle for the second wing stay bolt, plenty of thickness for the bolt (but will use loctite to be safe).

Used my wheel's spokes as a guideline to give me the IVA coverage with the cycle wings. 10 spoke wheels, 36 degree per spoke.
Popped one spoke at 12 o clock, needed to cover one spoke forward of the 12oclock for the 30 degrees required, and the wing covers 2 spokes rearwards so I'm covered to 72 degrees there (50 needed for iva).

[sheffjohn]

Fronts took a little longer. Mainly because I snapped all 3 brake shield bolts on the OSF when I was stripping the donor suspension.
Drilled those out, and borrowed a DECENT set of taps from one of the lads to sort the 6 holes out to mount the 2 front stays.
**tip** get decent taps ! The Sherwood set I borrowed cuts a thread far superior to the sh*te my machine mart taps did.





Went for the same method to line the front arches up to iva regs, and touch wood they seem to match from the front on view !



Can also see wing mirrors on that last pic. I welded a shaped plate, just below the 'dashboard' tube, at the top of the triangle formed by the side bars.

EBay supplied me some mirrors which were listed as sva compatible, so hopefully I'll be fine. These are just mounted through the plate and held with a nut. Quite like how you can't see the mounting area until your up close or looking for it, as it sits behind the tubes as such.

I haven't actually checked the mirror for iva angles yet. If I need to move them I will, but I'm happy with the view it gives me from where they are. So this shall be final position, even if they get moved temporarily.

[backspace]

Nice. It looks great!