September 6th 2006
Heat and Sound Insulation
In the pic below I have covered the bulkhead panel in a heat and sound insulator.
Another view of the same panel
The same material has been used on the back of the electronics panel. This is pictured below.
In the pic below you can see the 2" hole that has been cut through the electronics panel and also through the bulkhead. This was done in one operation with a holesaw.
If you look below the supercharger in the next pic you can see the hole and the gromet in the bulkhead panel. I an still having issues with the supercharger touching the bulkhead. The supercharger is now off again and I will have to grind away more material to allow for clearance. A am also in the process of getting a smaller pulley which will help with the clearance and give more boost. I was going to do this in one step (pulley size), but now it may be in two.
In the pic below you can see that the offside exhaust header and system have now been fitted.
24th SEPTEMBER 2006
THE BIG PUSH!
Since the last update I have been very busy on the car and seen my 40th birthday come and go. I will soon have the perfect mid-life crisis vehicle.
So what's been happening? Loads, infact I should be able to switch on the ECU tomorrow and fire up the fuel pumps.
THE ELECTRONICS PANEL
The panel is almost complete with only a few earth connections to make. The traction control will not be wired in until Christmas. The reason being that I don't have the time to do the work and it won't be needed until after the engine has been run in.
In the pic below some of the components have been secured in place.
In the pic below all of the components are now in postion and secured in place.
From left to right we have the MSD (Multi Spark Discharge) unit, next is the Racelogic traction control unit with the black knock contol unit on its back, next to that is the Aeromotive Pump Speed Control, next to that is the ECU, next to that is the Lamda Senor Interface and next to that is the Injector Driver Unit. There are also two relays and two fuse boxes.
The pic below shows the two end panels. One fitted with two small fans and one without. Aluminium mesh has been fitted to the holes made in the panels.
The pic below shows the end panel fitted and I have added a blue LED to show that the fans are on. The LED is lit in the pic. The fans will be controlled via a thermal switch so that they will be automatic in operation.
The pic below shows the panel almost finished. I have also fitted back the carpet around the panel.
Another view of the panel. All the wires will be neatened on completion.
In the pic below the panel is fitted with its carbon fibre lid. It is made of pre-preg autoclaved carbon. I bought a sheet and cut the lid to size with the Dremel.
THE CHARGECOOLER
The brackets have now been finished for the fitting of the chargecooler. The header tank has also had a bracket made and has been fitted to the bulkhead. The two hoses from the pre-rad have been connected to the header tank and pump. The chargecooler itself will be finally fitted tomorrow.
The pic below shows the upper bracket for the chargecooler. It is made of 3mm aluminium sheet with three 25mm rubber lined stainless P-clips fitted with countersunk machines screws fitted. The three holes at the top bolt to the flange on the chargecooler.
The pic below shows the lower bracket. It is made of 3.5mm flat aluminium bar bent and drilled to fit.
The pic below shows the header tank with its bracket made and fitted.
The pic below shows the pump for the chargecooler. It is a Davies Craig booster pump. The hoses have a 19mm internal diameter.
The pic below shows the header tank fitted and the lower hose connected. The top hose will come from the chargecooler itself. The pic also shows the thermal mat that I have fitted to the fuel tank. This has been done to both tanks. The pump is just out of view under the fuel fill panel.
OTHER THINGS
The coolant system on the car is now complete and filled. The alternator has been wired. The new battery has been fitted plus many other things. More to come soon!
Below is a pic of how the engine looks now.
Roll on next week!