- Thread starter davenport
- Start date
well aint done much recently but been plugging away at annoying stuff.....
boring shizzle first:
digital dash all mounted up
wheel speed sensor + buttons to control the dash ordered
next up.. the eternal issue of fitting tumpets to bike bodies...
silicone tube or the satchell/brown internal beasts were the only real options... but being me i`m doing it differently!!!!!!
a friend of mine did this on his 205/s16/busa bodied car so i know it`ll work!!
some ally flanges are being laser cut that i`ll weld onto the bodies and tap to M6, these will give me the option to fit any 48mm jenvey trumpet (90, 112 or 120mm being my current choices)
to make sure everything is spaced perfectly and the flanges are parallel i also drew a jig up to bolt the flanges to and sit on the bodies during welding..
finally the stainless flange is to bolt onto the ends once welded so i can dremel them clean and get the 48mm bore bang on!!
and.. by the joys of "DWG to image convertor" i give you what i sent to the profilers!
i may very well also do the same on the other end to so the bodies can be bolted had onto the inlet fannymold.....
boring shizzle first:
digital dash all mounted up
wheel speed sensor + buttons to control the dash ordered
next up.. the eternal issue of fitting tumpets to bike bodies...
silicone tube or the satchell/brown internal beasts were the only real options... but being me i`m doing it differently!!!!!!
a friend of mine did this on his 205/s16/busa bodied car so i know it`ll work!!
some ally flanges are being laser cut that i`ll weld onto the bodies and tap to M6, these will give me the option to fit any 48mm jenvey trumpet (90, 112 or 120mm being my current choices)
to make sure everything is spaced perfectly and the flanges are parallel i also drew a jig up to bolt the flanges to and sit on the bodies during welding..
finally the stainless flange is to bolt onto the ends once welded so i can dremel them clean and get the 48mm bore bang on!!
and.. by the joys of "DWG to image convertor" i give you what i sent to the profilers!
i may very well also do the same on the other end to so the bodies can be bolted had onto the inlet fannymold.....
a bit of a s*itty day sunday!! during 1 of the many "sit in the car and make rev noises!" sessions i noticed that when strapped in the top of the dash was obscured by the top of the steering wheel!! a MAJOR oversight on my part.. partly due to me now using a smaller wheel and also dropping the colomn slightly from standard..
but!! despite being busy at work.. tea breaks + lunch = opportunity!!
1 new blanking plate and bracket to hold the display unit..
that bolts nicely onto the stalk mount on the colomn
it needs a tweak clockwise but at least i can see the full display now!!!
fingers crossed a few coats of etch+primer at work tommorow and i can have them all satin black`d ready to fit at the weekend!!
but!! despite being busy at work.. tea breaks + lunch = opportunity!!
1 new blanking plate and bracket to hold the display unit..
that bolts nicely onto the stalk mount on the colomn
it needs a tweak clockwise but at least i can see the full display now!!!
fingers crossed a few coats of etch+primer at work tommorow and i can have them all satin black`d ready to fit at the weekend!!
the dash mount and infill are painted...
the laser cut shizzle arrived today so...
steel jig had the ally flanges bolted up to it.. it was then layed onto the bodies and they were tiggy-tig`d onto the bodies..
hey presto all cleaned up and the world of jenvey trumpets is all mine!!!
on a boring techy geek note... just gotta say the ally used in the gsxr castings was VERY nice to weld.. suprising clean compared to some of the ****e i`ve tried in the past!!
also a BIG thankyou to Jason@polarsystems for the quick (and cheap) laser cutting....
the laser cut shizzle arrived today so...
steel jig had the ally flanges bolted up to it.. it was then layed onto the bodies and they were tiggy-tig`d onto the bodies..
hey presto all cleaned up and the world of jenvey trumpets is all mine!!!
on a boring techy geek note... just gotta say the ally used in the gsxr castings was VERY nice to weld.. suprising clean compared to some of the ****e i`ve tried in the past!!
also a BIG thankyou to Jason@polarsystems for the quick (and cheap) laser cutting....
inbetween perving at the birds friend and supping beer with northernphil + TDFmatt things have been done... HONEST!
matt talked me through things i have to do before its ready to get wired (as it happens i`m a bit closer than i thought so thats a WIN)
i then got thinking about that de-servo idea like on the JAMmotorsport maxi ...
after speaking to some bloke from JAM 2 things became apparent..
1- there ****ing ****e at customer service and despite 2 calls they still haven`t got back to me with a price
2- when quized about just what goes into the kit they got a bit cagey and just mentioned "modified std parts"
so i did the only sensible thing....
yes folks i ripped the servo apart!!!
the important bits are the 2 items at the bottom..
the gold part fixes to the rocker on the bulkhead and pushes against the black part inside the servo and that in turn fits into the master cylinder and pushed the fluid...
so... in doing away with the black bit the servo can be binned and i can machine up an ally plate (20mm thick) and mount the master cylinder onto that!!!
something like this!!:
happy days!!
i also started machining up the bungs for the secondary butterfly holes in the bodies...
these get pressed into the body and will be peened (posh term for HIT) so they stay put.. the inside can then be ground flush to the bore...
seeings as the dash will get al its info from the wheel speed sensor i needed to block the speedo cable drive hole in the box so...
take a chunk of ally...
add a lathe and a lunch break and hey presto..
even took the time to cut a groove to reuse the std rubber Oring...
matt talked me through things i have to do before its ready to get wired (as it happens i`m a bit closer than i thought so thats a WIN)
i then got thinking about that de-servo idea like on the JAMmotorsport maxi ...
after speaking to some bloke from JAM 2 things became apparent..
1- there ****ing ****e at customer service and despite 2 calls they still haven`t got back to me with a price
2- when quized about just what goes into the kit they got a bit cagey and just mentioned "modified std parts"
so i did the only sensible thing....
yes folks i ripped the servo apart!!!
the important bits are the 2 items at the bottom..
the gold part fixes to the rocker on the bulkhead and pushes against the black part inside the servo and that in turn fits into the master cylinder and pushed the fluid...
so... in doing away with the black bit the servo can be binned and i can machine up an ally plate (20mm thick) and mount the master cylinder onto that!!!
something like this!!:
happy days!!
i also started machining up the bungs for the secondary butterfly holes in the bodies...
these get pressed into the body and will be peened (posh term for HIT) so they stay put.. the inside can then be ground flush to the bore...
seeings as the dash will get al its info from the wheel speed sensor i needed to block the speedo cable drive hole in the box so...
take a chunk of ally...
add a lathe and a lunch break and hey presto..
even took the time to cut a groove to reuse the std rubber Oring...
Seventynine
Member
- Messages
- 51
you're making me feeling bad about bunging up my 2nd butterflies with chemical metal 
very nice install and some really clever thinking
very nice install and some really clever thinking
bleedin hell... its been a while....
well in honesty i aint done much money`s been going elsewhere and the rattlebox has been sat under its cover... however.. things are starting up again..
finally got my ECU and CAN cavle to drive the digital dash..
also got time to sit down and think about the doorbar gussets... i could have just done simple ones.. but wheres the fun and impracticality in that...
so after taking some inspiration from a clio that is often at a friend of mines:
i drew up these.. there off being laser cut and can be popped in shortly..
well in honesty i aint done much money`s been going elsewhere and the rattlebox has been sat under its cover... however.. things are starting up again..
finally got my ECU and CAN cavle to drive the digital dash..
also got time to sit down and think about the doorbar gussets... i could have just done simple ones.. but wheres the fun and impracticality in that...
so after taking some inspiration from a clio that is often at a friend of mines:
i drew up these.. there off being laser cut and can be popped in shortly..
as i mentioned in post 145.. the servos being binned but the company in question JAMmotorsport were useless in either returning calls/being helpful/finding out a price..
so.. after i did a CAD drawing for my mate spanky and gave him a billet to play with.. he returned with this:
once again the lads played a blinder!! in return i`m gonna weld some seat rails into his golf to fit a bucket seat.. seems a fair swap tbh...
so.. after i did a CAD drawing for my mate spanky and gave him a billet to play with.. he returned with this:
once again the lads played a blinder!! in return i`m gonna weld some seat rails into his golf to fit a bucket seat.. seems a fair swap tbh...
decided to see if spanks machined item fitted earlier...
despite having been a CAD draughtsman for 5 years.. and being a machinist/fabricator/tinkerer for well over 16 years theres STILL always a niggle in the back of my head saying "what if i mis-measured something" this voice gets a LOT louder when someone else has invested time in the job.. however!!
the first 4 bolts went in a treat......
then i lined up the master cylinder and gave it a push...
happy days!!! a quick tweak on the brake bar to remove any slack in the linkage and the job was declared a winner!!!!
big big big thanks again to the mighty spank!! swarf producer par excellence!!!
i also took a pic of the worlds shortest 106 throttle cable lol
despite having been a CAD draughtsman for 5 years.. and being a machinist/fabricator/tinkerer for well over 16 years theres STILL always a niggle in the back of my head saying "what if i mis-measured something" this voice gets a LOT louder when someone else has invested time in the job.. however!!
the first 4 bolts went in a treat......
then i lined up the master cylinder and gave it a push...
happy days!!! a quick tweak on the brake bar to remove any slack in the linkage and the job was declared a winner!!!!
big big big thanks again to the mighty spank!! swarf producer par excellence!!!
i also took a pic of the worlds shortest 106 throttle cable lol
Your in the premiership league when it comes to the design and building of this car .It's been a gripping read you should flog your story to a magazine and get some pennies to help fund some more work, most car magazines I have read get off on changing a light bulb .
Neil
Neil
lol thank you very much for the praise...
PPC is about the only mag that attracts my attention for any longer than a "medium" length toilet break tbh... and even then i`ll only buy it occasionally...
as for today...
the postie delivered some limited edition jenvey vuvuzelas....
unfortunatly the wide end was 90mm and the spacing on the gsxr1000 bodies is only 80mm so they needed a bit of a trim up.. nothing to major though...
luckily i`d kept the jig i had lasercut to weld the flanges onto the bodies so that was dusted off and used to make sure everything would fit once i get down the workshop..
PPC is about the only mag that attracts my attention for any longer than a "medium" length toilet break tbh... and even then i`ll only buy it occasionally...
as for today...
the postie delivered some limited edition jenvey vuvuzelas....
unfortunatly the wide end was 90mm and the spacing on the gsxr1000 bodies is only 80mm so they needed a bit of a trim up.. nothing to major though...
luckily i`d kept the jig i had lasercut to weld the flanges onto the bodies so that was dusted off and used to make sure everything would fit once i get down the workshop..
well.... they fit......
any longer and the ****ers would be in the cab with me...
i also started cleaning up the drivers side driveshaft as it needs a new intermediate bearing.. i also spotted a split in the inboard gaitor so decided the best thing to do was strip the ****ing lot.. clean it all up.. paint the exposed bits and rebuild with new gaitors.. (WILL DO BOTH SIDES!)
drivers side stripped down and 90% cleaned....
any longer and the ****ers would be in the cab with me...
i also started cleaning up the drivers side driveshaft as it needs a new intermediate bearing.. i also spotted a split in the inboard gaitor so decided the best thing to do was strip the ****ing lot.. clean it all up.. paint the exposed bits and rebuild with new gaitors.. (WILL DO BOTH SIDES!)
drivers side stripped down and 90% cleaned....
Two words!..............My Hero!!! Firstly id like to say that this is a quailty write up, very detailed and i love the way it is has been writen..........from a engineering/manufacturing point of view rather than a shopping list build like some on the net!
Im currenltly building a hyundai for stage rallying and will soon will be faced with the same challenges you have been faced! So its always nice to see other people ideas! Im very jelous of all the machinery you can get your hands on! would kill for the space/budget for a mill and lathe!
Anyway keep up the good work! As its definatly getting there! Cant wait to see more!
Oh and a small note; I know its been mentioned but id doubt it very much if a scrutineer would be happy with the location of fuel pump and all the joints in the cabin! (might be worth asking about)
Im currenltly building a hyundai for stage rallying and will soon will be faced with the same challenges you have been faced! So its always nice to see other people ideas! Im very jelous of all the machinery you can get your hands on! would kill for the space/budget for a mill and lathe!
Anyway keep up the good work! As its definatly getting there! Cant wait to see more!
Oh and a small note; I know its been mentioned but id doubt it very much if a scrutineer would be happy with the location of fuel pump and all the joints in the cabin! (might be worth asking about)
Keep those updates coming!MJ - yeah for back roads and track days the fuel system isn`t an issue BUT if i decide to see just how bad i am at driving and try me hand at competing the scrutes will definatly have issues...
at the minute the tank i`ve made is about 7litres up on standard capacity as i`m intending on doing a few top-gear style european road trips once its done so getting as much range as possible was the issue...
if i was competeing then range becomes less of an issue and i think i`d make another smaller tank and incorporate an internal collector inside the shell and then mount the high pressure pump inside there too and then run the pipes UNDER the car and have a lid on the tank box secured with a few DZUS fasteners....
as for the space/equipment access... yeah im MAJORLY lucky to be in the position i am and without a doubt this car would not be possible if i wasn`t...
this week has seen a few more mods/tweeks/purchases..
4 new gaiters:
also.. after being inspired by this hideously expensive KRS lower engine mount i got busy mocking 1 up in ally...
luck is most definatly with me as it fitted!!
and everything looked inline
ordered 2 rosejoints from mcgill and will machine up an ally joiner next week once the length is confirmed.. the ally MOK-up (made-of-krap! lol) has been refined and remade in 3mm stainless steel
i also got a new battery:
at the minute the tank i`ve made is about 7litres up on standard capacity as i`m intending on doing a few top-gear style european road trips once its done so getting as much range as possible was the issue...
if i was competeing then range becomes less of an issue and i think i`d make another smaller tank and incorporate an internal collector inside the shell and then mount the high pressure pump inside there too and then run the pipes UNDER the car and have a lid on the tank box secured with a few DZUS fasteners....
as for the space/equipment access... yeah im MAJORLY lucky to be in the position i am and without a doubt this car would not be possible if i wasn`t...
this week has seen a few more mods/tweeks/purchases..
4 new gaiters:
also.. after being inspired by this hideously expensive KRS lower engine mount i got busy mocking 1 up in ally...
luck is most definatly with me as it fitted!!
and everything looked inline
ordered 2 rosejoints from mcgill and will machine up an ally joiner next week once the length is confirmed.. the ally MOK-up (made-of-krap! lol) has been refined and remade in 3mm stainless steel
i also got a new battery:
with 90% of the bits to hand i decided it was time to find a place for it all......
after a few trials and a lot of... "no, that looks s*it... no, that`ll make wiring harder... no, theres not enough room" i think i`ve found it...
to celebrate.. i made a cage for the battery:
and just incase any lanky passengers manage to squeeze past all the door bars i`ll make a footrest out of this:
i think this originally came off a mercedes actros HGV but can`t be sure... whatever its origin its now mine and FREE!!!
after a few trials and a lot of... "no, that looks s*it... no, that`ll make wiring harder... no, theres not enough room" i think i`ve found it...
to celebrate.. i made a cage for the battery:
and just incase any lanky passengers manage to squeeze past all the door bars i`ll make a footrest out of this:
i think this originally came off a mercedes actros HGV but can`t be sure... whatever its origin its now mine and FREE!!!
Endacy
Member
- Messages
- 278
Loving the work on this car, lots of nicely made bits.
Looking at the battery cage, where the top plate is bent over near the terminals, won't it interfere with the terminal clamps and short out the +ve to earth? Or are the terminals further away than they look, or are there slimline clamps you have?
Looking at the battery cage, where the top plate is bent over near the terminals, won't it interfere with the terminal clamps and short out the +ve to earth? Or are the terminals further away than they look, or are there slimline clamps you have?
