Morgans Exocet build thread

[hammy3601]

Aug 31, 2019 11:52:44 GMT bewgy said:

I tried the noise test today, ran the engine upto 5,000 rpm with my phone 500mm behind the exhaust in the direction the exhaust is pointing. The maximum noise level was 90 dba, IVA states 99 so I think I do not need to add a silencer. I am running the same mid box and silencer as you, maybe the flexible hose helps?

I do have some small leaks at two of the joins but don't think that would make a difference? Did you say that you was getting 115, that's really loud, maybe the try with a different app.

Don't think my neighbors were best pleased today...

My car failed emissions due to exhaust leaks, I was using flexi and joiners. Fixed by custom exhaust at Skuzzle

[themorgster]

I made a longer loom for the rear cover to make it easier to unplug hen removing the cover. The problem was what to do with the excess cable inside hitting the tank. Plumbers pipe clips screwed to a piece of plastic and bonded to the inside of the cover seems to answer.



I also fitted a rear plate mount.

[themorgster]

I thought I’d replace the 20 year old rubber seals and filters on the injectors. Not a big or expensive job, also gives the chance to clean the inside of the inlet manifold. I have a 1999 NB Mk2 1.8 which has a 2 piece manifold, only the top needs removing to access the fuel rail (which does not need to be disconnected). Removing the filters can be a bit tough, but a self tapper and a good strong steady pull gets them out... eventually!

[themorgster]

Fitted the grille and front number plate mount. I had so much grille left over that I made an extra one for the radiator. The 2 layers of grille give a funky 3D effect. Copious amounts of PU adhesive keeps the grille in place nicely. I wrapped a piece of wood in cloth and then used it as a brace with bungees pulling the grille forward to fit the contour of the hole. Note: the numberplate is just an old one I have in my garage, i know it can’t go on the car😉

[themorgster]

Starting to get there now... just a bit of wiring tidy up, headlight modification, the firewall, transmission tunnel, sides, IVA/edge rounding, wheel refurb & tyres and I’m done!

[camspeed]

Hi, 

Great car, great build. I am new to this but not new to building race cars.

I will take up some of your ideas too......great pics with the posts.

If you don't mind me pointing out an issue I have come across with the bonnet latches you have fitted? I would hate you to have the issue I have on a G Type in my workshop. This car was/is well built and certainly not an obvious error or design issue from MEV. I think its a combination of the catch style and catch location. 


The bonnets flex at speed if not firmly secured further forwards and/or too high up.. I have a G Type where the rad brackets had started punching holes in the bonnet  sides. It needed a secondary fixing to take the movement out of the bonnet or a firmer fixing around the front wheels and some padding around the brackets perhaps. Statically it looks fine with plenty of clearance. But country lanes and a spirited drive might cause the same problem.

I am sure you have your own ideas on how to sort it out? 


Pics attached. If I am posting something you already know or in the wrong place please delete this...….I am the newbie here.

Cheers,

John

[themorgster]

Thanks for the heads up. I had noticed that could be an issue so I fitted rubber stoppers to the rad mount bolts (see below). I’m also considering putting additional fasteners low down at the front for additional piece of mind!

[themorgster]

I rotated the Dominator lenses and changed the bulbs for some Philips X-tremeVision ones. In the photo below the original bulb is on the left.

Dipped beam


Full beam

[themorgster]

I have decided that a spiral insert is the best solution to my excessive exhaust noise (110dB+) problem without killing the power. Making the inset (like the one below) should be relatively cheap and easy by welding (cut & bent) M16 50mm penny washers to a bit of 16mm OD tube. Then I just have to shove it in the rear glass pack silencer and work out a way of securing it.

[jleigh5]

How did you test that the noise was 110db? I used a free app on my phone that said my Exocet was 120db, but it didn’t seem too loud so bought one off amazon to check (£15 with next day delivery), which read 93db, so didn’t change anything in the exhaust.
I have a 1.8 1999 mk2 too with just the cat and the mev rear box (no other silencer)
The tester used at IVA was outdoors, asked me to hold revs at 4.5-5k and showed 92db, so as far as my experience goes the free apps are way off.

[themorgster]

I appreciate the advice...if only that were the case... I used a dB meter that my next door neighbour lent me. He does track days in his MX5. His meter registered +/- 3dB vs those used at tracks on his car, so I’m assuming it’s fairly accurate.

MEV’s rear silencer has been designed and tested to be IVA compliant, so a safe choice, mine is a straight through glass pack muffler (x2) which (to my ear) sounds like a demon spitfire from hell - awesome, but wayyyy to loud!

I have considered getting the MEV silencer, but to be honest, I’m just having fun knocking things up to see what works. I’ve missed my summer 2019 target so I’m just taking my time enjoying the process of trial and error!

[camspeed]

I must say the MEV system really does suit the style of the car.
I looked at building my own system but when you look at the space available and what looks good then the MEV box is nice. I want to try and keep a flat floor too.

If I didn't go for that then I was looking at an off the shelf repackable centre box with twin rear pipes coming up from the rear subframe with nice rolled ends.

I love your spiral idea, did the similar on an RX7 MK1 years ago. worked very well.

[themorgster]

I knocked up the spiral and put it in the muffler... it works! The car is on stands in the garage so I can’t do a metered test but it is noticeably quieter.


I’ve also been busy mounting the fog, dash dimmer and hazard switches. initially I was going to mount them on the wiring tray, but as I have a harness seatbelt, I wouldn’t to be able to reach them when driving (an IVA fail), so I put them under the dash pod.

[themorgster]

Gearing up for IVA prep I made a 100mm contact hemisphere using a metal hemisphere off eBay and a bit of old 22mm water pipe PU’d to it.

rover.ebay.com/rover/0/0/0?mpre=https%3A%2F%2Fwww.ebay.co.uk%2Fulk%2Fitm%2F132832356238

[themorgster]

I’ve been a busy boy fitting my rear interior panel, battery box, firewall and trans tunnel.

I made up some brackets that clamp the battery & box to the floor behind the drivers seat. I considered locating it behind the passenger seat (for weight distribution) but want to keep that space free for luggage etc.





I had to cut a much larger hole in the trans tunnel than anticipated for the gear lever, not sure if the 6-speed box is different, or all protrude by the same amount.