Hi Patrick,
where did you get your propshaft?
Are you using the 'rubber doughnut' between the gearbox and the propshaft?
regards
Peter
3 Nov 2005, 9:38pm
Build progress
3 Nov 2005, 10:19pm
Hi Peter, the propshaft is from Marlin made to specification. Unfortunatly it wont adjust far enough for the rubber doughnut - it gets longer but not shorter. I might need to have a chat with Terry about it. However seeing as its new and balanced I dont think it will be a problem (I hope anyway!)
9 Nov 2005, 9:26pm
Brakes installed at the weekend. I've only just got around taking pictures! The clock turned up as well today. Unfortunatly it does not match any of the rest of the dials we already have. So I'm going to have to send it back.
19 Nov 2005, 2:54pm
After a bit of break working on the car the handbrake system is coming together this weekend. Two bolts serve as ends for the handbrake cable attached:
5 Dec 2005, 7:46pm
Slightly off topic, but I thought I would see what the BMC airbox sounds like that I bought for the Sportster. So I hooked it up to my daily driver this weekend for a laugh! Here's the results:
Click to download (1.8Mb) - Xvid
On the Sportster I will be using the cold air feed pipe with will reduce the noise a little bit - but will get nice cold air in the engine!
I didnt go for a drive because of the 'mad max' style installation!
Click to download (1.8Mb) - Xvid
On the Sportster I will be using the cold air feed pipe with will reduce the noise a little bit - but will get nice cold air in the engine!
I didnt go for a drive because of the 'mad max' style installation!
11 Dec 2005, 6:23pm
The stock exhaust is a two part system. Today we test fitted the manifold and first part to see if the steering column clear it. It does which it good! Seems the issue with the steering column is that the hole in the bulk head is in the wrong place. If its moved over then the steering column will bolt on to the mount without an adapter plate.
We'll get a custom exhaust made anyway so its less of an issue!
In a strange twist the postman showed up today, Sunday! The replacment clock from Marlin arrived, this one now matches the rest. They look really good all lined up together.
We'll get a custom exhaust made anyway so its less of an issue!
In a strange twist the postman showed up today, Sunday! The replacment clock from Marlin arrived, this one now matches the rest. They look really good all lined up together.
11 Dec 2005, 9:33pm
Hi Patrick,
that's good news about the exhaust manifold.
I just noticed that there is a new Marlin price list on their website that lists a Sportster E30 manifold and exhoust system for £775, ouch!
I am planning on a diy exhaust system to start with, but i'm not sure how easy this is going to be
I have bought the fuel swirl pot and both high and low pressure fuel pumps, so will persist with this design.
It will be interesting to compare results.
best regards
peter
that's good news about the exhaust manifold.
I just noticed that there is a new Marlin price list on their website that lists a Sportster E30 manifold and exhoust system for £775, ouch!
I am planning on a diy exhaust system to start with, but i'm not sure how easy this is going to be
I have bought the fuel swirl pot and both high and low pressure fuel pumps, so will persist with this design.
It will be interesting to compare results.
best regards
peter
11 Dec 2005, 9:43pm
Hi Peter,
I recon that for that sort of money I can get an exhaust made to my specification which it why I've not signed up for the Marlin one as I want to get some quote else where first.
I might go Robin's route and use 1 fuel pump and get a baffle put in the tank.
I recon that for that sort of money I can get an exhaust made to my specification which it why I've not signed up for the Marlin one as I want to get some quote else where first.
I might go Robin's route and use 1 fuel pump and get a baffle put in the tank.
21 Dec 2005, 12:00pm
Patrick - rewinding your build a bit:
The paint you used on the engine block - high temp resistant, obviously, but is it especially for aluminium? I was led to believe that painting alu was a pain in the ass...
The paint you used on the engine block - high temp resistant, obviously, but is it especially for aluminium? I was led to believe that painting alu was a pain in the ass...
21 Dec 2005, 12:07pm
I used this stuff:
http://www.frost.co.uk/item_Detail.asp?productID=8763
I was just going to paint the block, but ended up doing the sump as well which is the only ali bit i painted.
As for the rocker cover and intake manifold I use a spray can of UHT stain black. I think it was a can of this stuff: http://www.frost.co.uk/item_Detail.asp?productID=8219
http://www.frost.co.uk/item_Detail.asp?productID=8763
I was just going to paint the block, but ended up doing the sump as well which is the only ali bit i painted.
As for the rocker cover and intake manifold I use a spray can of UHT stain black. I think it was a can of this stuff: http://www.frost.co.uk/item_Detail.asp?productID=8219
21 Dec 2005, 1:23pm
From you answer, I assume that the block is cast iron - I had got it into my head that it was aluminium.
What a school boy error...
What a school boy error...
21 Dec 2005, 1:33pm
From you answer, I assume that the block is cast iron - I had got it into my head that it was aluminium.
What a school boy error...
What a school boy error...
Yeah
the M20 is iron. I did some wire brush work to remove the rust and the did the final clean up with: http://www.frost.co.uk/item_Detail.asp?productID=8229
30 Dec 2005, 6:27pm
The holiday season has given us time to sit next to the car and think about how and where to run things. The intake is going to be a rather interesting one. I'll let the pictures do the talking once all the bits turn up from Rally Design.
Ordered are silicon hoses, ducts, oil cooler and pipes. After further consideration we're moving the rad further forward, placing the oil cooler in front and getting a "sucker" fan instead. The current position places the rad too close to the engine for me to be comfortable with.
Also up for work is the steering column. After enlarging the hole on the bulk head we were able to mount it using the bracket already in the car. However after spending some time sitting in the driver seat we both agreed we didn't like the alignment and have decided to customise it. Using the brake we already made and the now enlarged hole I think we have a steering position that suits our personal taste.
The brake pedal - after several hours of going nowhere trying to bend it, it's time to call in a professional. This stuff is too thick for our weedy gas burner and vice to bend.
The Rally Design order came today, so we've been able to start putting the intake together!
Here are some pictures:
Oil cooler
Intake system
Steering column bracket test fit
Ordered are silicon hoses, ducts, oil cooler and pipes. After further consideration we're moving the rad further forward, placing the oil cooler in front and getting a "sucker" fan instead. The current position places the rad too close to the engine for me to be comfortable with.
Also up for work is the steering column. After enlarging the hole on the bulk head we were able to mount it using the bracket already in the car. However after spending some time sitting in the driver seat we both agreed we didn't like the alignment and have decided to customise it. Using the brake we already made and the now enlarged hole I think we have a steering position that suits our personal taste.
The brake pedal - after several hours of going nowhere trying to bend it, it's time to call in a professional. This stuff is too thick for our weedy gas burner and vice to bend.
The Rally Design order came today, so we've been able to start putting the intake together!
Here are some pictures:
Oil cooler
Intake system
Steering column bracket test fit
2 Jan 2006, 7:06pm
I spent a little time today revising the layout of the intake, its now shorter and less complex. The shelving rail and brackets need replacing with something a bit better 
:
:
5 Jan 2006, 8:35am
The oil & water unions are here! What I didnt realise is that the T piece had the right thread for the oil pressure sensor so I have one too many bits. Anyway on to the important stuff:
Installation:
Parts:
Installation:
Parts:
8 Jan 2006, 12:19am
We got the brake pedal back from a friend who was able to bend it for us. Now the positioning is much better giving more room between the accelerator mand brakes (we've got big feet!):
15 Jan 2006, 5:41pm
Oil cooler fitment and revised radiator fitment:
23 Jan 2006, 1:25pm
Order from Car Builder Solutions turned up today, placed on Friday afternoon! One heater and plume, a rivnut gun, universal band and a set of dash warning lights (I really didnt like the ones that came with the kit so I order these instead):
I've done a lot of work on the steering column bulk head mounting on sunday, it was nice and sunny so out the driveway! I've not put any pictures up yet.
I've done a lot of work on the steering column bulk head mounting on sunday, it was nice and sunny so out the driveway! I've not put any pictures up yet.
12 Feb 2006, 5:09pm
A number of new items this week! The modified tank is complete, the oil pipe connections are prepared for clean up. Finally much of the coolant system is planned out and ready to finalise:
19 Feb 2006, 4:03pm
Time for another version of the radiator bracket! Its now bolted along the sides with two strips of metal either side of the rad. Bolts need shortening to and a lick of paint to clean it up.
All the water pipes for the front of then engine are now cut to size and routed. Currently the bottom pipe is zip tied to the bottom of the radiator - I'd like to find a more elegant solution for this but it will do for the moment.
Oil pipe test fit, not sure yet how we're going to run these so these are just where they will fit at the moment. The oil cooler connectors we have are the straight type so are most suitable for running the pips this way. 180 degreee connector would work for going under and along. More research need on this one!
All the water pipes for the front of then engine are now cut to size and routed. Currently the bottom pipe is zip tied to the bottom of the radiator - I'd like to find a more elegant solution for this but it will do for the moment.
Oil pipe test fit, not sure yet how we're going to run these so these are just where they will fit at the moment. The oil cooler connectors we have are the straight type so are most suitable for running the pips this way. 180 degreee connector would work for going under and along. More research need on this one!
26 Feb 2006, 9:19pm
Today we installed the fuel level sender in the fuel tank - sounds easy but it took most of the day! Stage 1 was to figure out the numbering system as the chart that came with the sender only when down to 180mm deep tanks. The Marlin tank is 160mm. Luckily it was quite an easy one to figure out - 160mm depth, 67mm pivot, 63mm radius.
Next on the list was to make the hole that the send goes in. It was all going well until the dremel (110v 20 odd year old model) finally giving in and died leave the rest of the cut out and clean up to me done by hand. Still turned out quite nicely:
There was a lot of mess in the tank, but luckily one of the vacuum cleaner attachments fits in the hole!
This only leaves figuring out how to attach the fuel hose to the tank and mounting the filter/pump!
Next on the list was to make the hole that the send goes in. It was all going well until the dremel (110v 20 odd year old model) finally giving in and died leave the rest of the cut out and clean up to me done by hand. Still turned out quite nicely:
There was a lot of mess in the tank, but luckily one of the vacuum cleaner attachments fits in the hole!
This only leaves figuring out how to attach the fuel hose to the tank and mounting the filter/pump!
5 Mar 2006, 5:13pm
Busy weekend! We've installed the car builder solutions heater and put the oil cooler pipes in. The oil return pipe on the engine recieved a new spring, washer and o ring. The steering column is back out to clean up the bracket that holds it and adjust the bottom bracket.
2 Apr 2006, 3:52pm
A quick trip to B&Q and one hardcore MAPP blow tourch later the two oil pipes are bent out of the way of the steering column with ease!
CBS Throttle cable through the bulk head. The thread on this had to be chopped back so the pedal could move all the way up. We've bolted on throttle cable at the other end - the cable is current 5m long which is a bit much! The throttle is still a bit stiff with the long cable - We're hoping that it will loose a bit once its shortend.
Parts from the donor heater system - The two pipes use opposite connector types therefore when connected we can use this as an inline electric controlled valve to regulate the amount of hot water that flows through the system from a control on the dash - much nicer than a manual valve hidden under the dash!
-----------------------
Following on from this thread: http://www.talkaudio.co.uk/vbb/showthread.php?t=151195
I'm looking for someone to build an exhaust for me:
Something good and something that's less than 101db (1 meter from tip - SVA req.)
Yes need a manifold too.
EDIT: Budget wise I've got around £800 to play with - maybe a bit more if its something really good.
Looks wise I'd like pipes out the side of the engine bay - like this only evenly spaced:
Finishing with the pipe on the side - similar to this only with 6 pipes:
Thank you! I will be updating the site later today with new pics as I've been busy this weekend!
EDIT:
As far as manifold design goes for the M20 engine - this is supposed to be very good - not good for me as I dont want an underbody exhaust:
http://www.xsperformance.co.uk/e30zone/catalog/images/btb23.JPG
CBS Throttle cable through the bulk head. The thread on this had to be chopped back so the pedal could move all the way up. We've bolted on throttle cable at the other end - the cable is current 5m long which is a bit much! The throttle is still a bit stiff with the long cable - We're hoping that it will loose a bit once its shortend.
Parts from the donor heater system - The two pipes use opposite connector types therefore when connected we can use this as an inline electric controlled valve to regulate the amount of hot water that flows through the system from a control on the dash - much nicer than a manual valve hidden under the dash!
-----------------------
Following on from this thread: http://www.talkaudio.co.uk/vbb/showthread.php?t=151195
I'm looking for someone to build an exhaust for me:
Patrick, do you want something good or something loud, badly made and bad for the engine?
Do you need the manifold making too?
Do you need the manifold making too?
Something good and something that's less than 101db (1 meter from tip - SVA req.)
Yes need a manifold too.
EDIT: Budget wise I've got around £800 to play with - maybe a bit more if its something really good.
Looks wise I'd like pipes out the side of the engine bay - like this only evenly spaced:
Finishing with the pipe on the side - similar to this only with 6 pipes:
didnt know you were building that. just looked through your site, and am impressed. nice read - well done
Thank you!
I will be updating the site later today with new pics as I've been busy this weekend!EDIT:
As far as manifold design goes for the M20 engine - this is supposed to be very good - not good for me as I dont want an underbody exhaust:
http://www.xsperformance.co.uk/e30zone/catalog/images/btb23.JPG
2 Apr 2006, 3:52pm
Heater pipes added - CBS sent the wrong size pipes - too small, managed to get them on anyway but they kink on the bends so will have to replace them. Probably with two 90 degree silicon hoses.
Fuel pipe straps - Doh! hmm should really have thought of this before making a big hole in the tank - never mind just moved the straps over.
Fuel pump, filter and connection in place:
Fuel pipe straps - Doh! hmm should really have thought of this before making a big hole in the tank - never mind just moved the straps over.
Fuel pump, filter and connection in place:
2 Apr 2006, 3:53pm
Wire, wires everywhere! We've started on the loom this weekend while waiting for the fuel pump! There's only a few bits on construction work left, the main one being the brackets for holding the AFM, airfilter and header tank. There's a few minor bit hose left and lots of hose clips!
On to the pictures, some working in progress on the wiring loom:
On to the pictures, some working in progress on the wiring loom: