Daniels Blue 182.

[dann2707]

Oh s**t yeah, completely forgot to say, the gearbox is all bolted on and in haha. Looks like i've moved the engine over more to allow the play I required as either side of the engine for the driveshaft...fingers crossed anyway.

 

[bashracing]

Good work Dan, keep chipping away at it you've got six months before the good weather returns so don't rush it.:up:

 

[rainbird]

Great result on the Kangoo pedal box dude, parts bin raiding FTW!

 

[dann2707]

Had some time today so sorted out the reservoirs to the master cylinder. Along with mounting the clutch reservoir which is all plumbed in now.

The brake ressys are mounted where they were before, used some alu sheet that I have bent and riveted to the car.

20171008_174015 by dann2707, on Flickr

20171008_174009_HDR by dann2707, on Flickr

Then the clutch bottle is mounted here, using a rivnut. Pipe fed through grommet to the master cylinder on the bulkhead

20171008_174022 by dann2707, on Flickr

You can clearly see the pipe feeding around here.

20171008_174400 by dann2707, on Flickr


I then bled the brakes using the forever alone kit and got a cracking feel. I'll re-bleed them next week to get allllll the air out as I didn't have enough time to do as proper as a job as i'd like.

I can then whip the engine back in and connect everything up although I now need to get a custom downpipe. Shouldn't be too hard to situate around the master cylinder.

 

[rainbird]

Hey Mister, can Boris come out to play soon? :nomouth:

 

[Louis]

I agree

 

[dann2707]

Will try and update tonight if I get a moment x

 

[rainbird]

Yaaaaay. Then come down and fix mine yeah?

 

[Mr Plums]

Whose this rainbird Dan?

Anything you wana tell us?

 

[dann2707]

Got a load of pics but I have absolutely no intention on using the forums uploaded as it takes forever and is awful to use. Will try Flickr later or summin

 

[Clio_fool]

Got a load of pics but I have absolutely no intention on using the forums uploaded as it takes forever and is awful to use. Will try Flickr later or summin

Photobucket works again now I believe. Seems they realised nobody was gonna be held to ransom for a few pic's.

 

[dann2707]

nothing to see here, dp

 

[dann2707]

Progress. In the form of a few pictures.

Got the engine back in. Excuse the garage mess at the moment. It is absolutely killing me seeing it in such a state.

20171104_172527 by dann2707, on Flickr

Voila

20171104_180110 by dann2707, on Flickr

I then started plugging everything in.

20171104_185709 by dann2707, on Flickr

Now I have messed around with the box mounts some more it's raised the gearbox up which means it's clearing a lot of things. Before the engine was resting on something.. more on that later for a lol story. The engine now happily swings on it's two mounts which is excellent news. Before when dropped in it was almost wedged.

So the next issue, the turbo being so close to the master cylinder. We all knew it was going to be an issue so just showing the issue in hand

20171108_203947 by dann2707, on Flickr

For reference and for those wanting to do the conversion (don't) this is how far away the turbo is to the mc. New custom downpipe required

20171108_204028 by dann2707, on Flickr

Plumbed more stuff in. Engine bay is looking scratty as f**k lately. Needs a clean or just to take pics without flash...

20171108_213324 by dann2707, on Flickr


Finally the engine is more level now compared to what it was like before. I don't have a before pic sadly. Not to hand anyway.

20171108_213401 by dann2707, on Flickr

Next things on the list:

Headshield for turbo. Maybe even a turbo jacket
Custom downpipe
new header tank bottle
o/s gearbox seal

 

[incy-spider]

Dude, look into ceramic coatings! Great for heat management

 

[Coops Mk1]

getting there yooooooooof

 

[dann2707]

Most bits plumbed in, car turned over very easily

Obviously didn't start though as I've remove fuel pipes as I'm making a return rail future proofing as everyone knows about the fuel starvation megs get.

 

[Mr Plums]

Nothing wrong with meg internals mate :astonished:

 

[dann2707]

Nothing wrong with meg internals mate :astonished:

Read my post again haha making a return rail so that the cylinders don't run lean.

 

[Mr Plums]

Read my post again :wink: haha making a return rail so that the cylinders don't run lean.

I know, i read it, im just saying theyre fine.

Mine popped 3 times in 20k, but that maybe due to a bigger turbo, i dunno mate.

 

[dann2707]

I'll be honest sexy pants, I have absolutely f**k all clue what you're talking about. I never mentioned Megane internals??

 

[Mr Plums]

I'll be honest sexy pants, I have absolutely f**k all clue what you're talking about. I never mentioned Megane internals??

I dont know what im talking about either buddy haha, but iirc you have a 225 engine fitted, and i have had 225 pistons let go 3 times now, including this time since the new owner of my old car has owned it

Im glad its getting there now mate.

 

[dann2707]

I dont know what im talking about either buddy haha, but iirc you have a 225 engine fitted, and i have had 225 pistons let go 3 times now, including this time since the new owner of my old car has discovered.

Im glad its getting there now mate.

Do you know what fuel set up you were running Tom? Was it a return set up?

 

[Mr Plums]

Do you know what fuel set up you were running Tom? Was it a return set up?

Im not sure buddy it was running the ph1 fuel reg etc but im not 100% sure on the return setup.

 

[barnesautos]

Im not sure buddy it was running the ph1 fuel reg etc but im not 100% sure on the return setup.

@Dan2707 . If the Ph1 rail was being used along with the pressure regulator, you’d be a fool to block it off if who ever fitted it had an ounce of sense. So going by that , I’d hazard a guess it was a return system .
Why Renault took it away in the Ph2 is prob cost lol

 

[Matt e]

i think its more to do with the age of the meganes now and most of the fuel pumps are at least 10 years old now and done 80k+. the mk3 meganes dont run a return line and they dont seem to have any troubles yet. and the fuel rail is centrally feed unlike the the mk2 where it goes in from the 1 side which help abit more

 

[dann2707]

Awesome evening. Got the clutch plugged up and bled. Bled like an absolute dream after taking mick at diamond motors advice on how to prime the slave. That feels amazing now. Also drilled and tapped my spare fuel rail with a 1/4 npt tap along with the fuel sender ready for the Fpr from demon Tweeks. That should be all sorted soon.

Booking the exhaust in soon too at a place near me. Very excited.

 

[dann2707]

Fitted the return lines tonight and the fuel pressure reg and housing is on the way from ebay. For anyone reading this in the future, a saxo 8v uses an external Fpr 3.5bar and you can pick them up for pennies. 2000 of them in fact.

Should have that up and running before I know it.

Total cost of the return set up.

Borrow a tap from work = free
Fpr £20
Fuel pipe £15
Return fittings £15
Ear crimps for fuel sender £3.50

Such a small cost for what is essentially removing the problem of cylinder 1 piston failure. Fun times

 

[dann2707]

i think its more to do with the age of the meganes now and most of the fuel pumps are at least 10 years old now and done 80k+. the mk3 meganes dont run a return line and they dont seem to have any troubles yet. and the fuel rail is centrally feed unlike the the mk2 where it goes in from the 1 side which help abit more

Small world. Just saw your post randomly on Megane sport. Derby though

 

[dann2707]

Right then, i'm finally at a computer so I can do a fairly big-ish update or at least an update that has encapsulated the last few weeks of working on Boris.

I've been really enjoying it again and having a heated garage has made a whole world of difference to my mood. I would never have been able to do any of this if I was at the side of the road so i'm lucky in that sense.

Firstly, the accelerator cable from the ph1 is now all in and connected however due to not having any carpet in the car the pedal could quite easily be overstretched which would snap the pedal so with a trusty m8 bolt and nut I now have a stop. Luckily that rivnut was already there from the pedal box.

You'll probably notice that there is infact a gaping hole in my floor too hahah, that needs welding over a bit.

20171120_204020 by dann2707, on Flickr

Random shot of the new wheel which I don't think I ever pictured despite it being 4 months ago or so. Really happy with the interior now.

20171120_205507 by dann2707, on Flickr

With the flash on, andddddddddd the wheel looks knackered already and it hasn't seen a single mile on the road haha

20171120_205519 by dann2707, on Flickr

We had a vehicle show at work in summer which was brilliant, probably around 30 vehicles turned up with 2 awards available. One for most interesting and one for best in show....

20171124_090207 by dann2707, on Flickr


Well happy with that result, especially as I had completely forgotten about an award to be handed out but this was the first engineering staff meeting we had had since summer. Quite a funny moment as I didn't pick up my trophy when the award was announced and tried to go back into the room to get it but I had to wait for c. 200 people to come out first and as I was stood by the door it looked like I was waiting for everyone to congratulate me as they left which they did hahahaha. awkwardddddddddd.

Moving swiftly on, fuel return line was next on the list of things to do. So I needed some pipe from the stock room ie back of my garage.

20171124_163408 by dann2707, on Flickr

The hole here is where I am taking the feed from for the vacuum servo.

20171124_164221 by dann2707, on Flickr


I then fitted the new rail with the 1/4 npt fitting which acts as the return for the fuel

20171124_180038 by dann2707, on Flickr

As the return now protrudes where the dipstick goes I had to drill a new hole in the dipstick holder and bend the bracket a bit, coupled with a little spacer it looks OEM ish

20171126_153312 by dann2707, on Flickr

I am not sure why I took this picture, there was probably some meaning behind it but I have no idea so here it is anyway.

20171124_180048 by dann2707, on Flickr


I then needed to create the return line into the sender unit. So at my trusty workstation ie kitchen breakfast bar I started assembling...

20171125_145934 by dann2707, on Flickr

This is a bit of fuel pipe attached to the return line, this will direct fuel back into the swirl pot.

20171125_152858 by dann2707, on Flickr

20171125_152905 by dann2707, on Flickr

The next two photos show it better as to where it is now pointing, its going down the side of the fuel pump itself directly down into the collection of fuel. This means that when it returns its not being returned to anywhere in the tank, but into the swirl pot so fuel is always there.

20171125_162708 by dann2707, on Flickr

May be able to see it better there, the black little tube pointing down.

20171125_163240 by dann2707, on Flickr

20171125_171337 by dann2707, on Flickr

I've got an inline filter on the way that I will be fitting to the feed fuel pipe.



Today's job was to fit the fuel pressure regulator. This is the jobby which I got from a saxo 8v. Runs at 3.5 bar so is absolutely perfect. My only gripe is that there is no decent mounting position for it but it's okay for now.

20171126_125125 by dann2707, on Flickr

Decided to mount it here, it's just held there in this pic

20171126_125151 by dann2707, on Flickr


Rivnut again to the rescue which I rivnutted to the coil pack bracket which would hold the FPR crudely.

20171126_131600 by dann2707, on Flickr

FPR cable tied to that bolt then pipe work fitted. Luckily I've kept a load of fuel connectors from before so i've used them where I can, as you can see on the FPR inlet there.

20171126_134605 by dann2707, on Flickr

20171126_134611 by dann2707, on Flickr

Stupidly I didn't buy enough hose, I honestly thought 5 metres would do both the feed and return but I was wrong so Ive had to order some more but in the mean time I wanted to try it all out so the return was directed into the petrol can. Turned the car onto ignition and voila. pressure was released after a little bit.

20171126_144227 by dann2707, on Flickr

I then wanted to start the car with the new set up, turned it over and boom, fired straight back into life although it sounded horrendous as it had no lambda or exhaust. The former because of the latter.

But overall i'm mega chuffed that it fired up despite the dicking around etc.

 

[Mr Plums]

Great write up mate, whats left to do now then before mapping?

 

[dann2707]

Great write up mate, whays left to do now then before mapping?

The car's already mapped haha. It will need a tweak but all this is in prep for the exhaust.

 

[Mr Plums]

The car's already mapped haha. It will need a tweak but all this is in prep for the exhaust.

Ahh right sorry mate, i knew you had it mapped but i thought with these fuel changes it might need tweaking, i cant wait mate, i honestly wish you the best of luck buddy, i know how frustrating it can be, fingers crossed everything goes hunky dory from now on :up:

 

[rainbird]

Tidy work on the return system mate, nicely done. I was going to suggest measuring your injector spacing as I have a spare 1.8t fuel rail somewhere which would be nice and tidy (has integrated FPR placement) but I think it'd want to be in the same location as your dipstick. I assume you've got the boost feed to the FPR connected up now?

 

[Jamess182]

Awesome work mate, coming along nicely. Would absolutely love a heated garage, must make a world of difference.
Would be good to see this once it's on the road, I'm in Derby area also.

 

[dann2707]

Tidy work on the return system mate, nicely done. I was going to suggest measuring your injector spacing as I have a spare 1.8t fuel rail somewhere which would be nice and tidy (has integrated FPR placement) but I think it'd want to be in the same location as your dipstick. I assume you've got the boost feed to the FPR connected up now?

Thanks mate! No it's not connected as of yet, I'm awaiting some vacuum line in the post for that and the vacuum to the servo. Should be all sorted this week all being well.

Awesome work mate, coming along nicely. Would absolutely love a heated garage, must make a world of difference.
Would be good to see this once it's on the road, I'm in Derby area also.

Thanks mannnnnn, where abouts in Derby are you? I'm so glad I made the move down here, I'm genuinely loving it.

 

[Gus]

Incredible work Dan.

 

[Jamess182]

Thanks mate! No it's not connected as of yet, I'm awaiting some vacuum line in the post for that and the vacuum to the servo. Should be all sorted this week all being well.



Thanks mannnnnn, where abouts in Derby are you? I'm so glad I made the move down here, I'm genuinely loving it.

No prob.
I'm in Belper mate. Think that's the first time I've heard anything remotely positive about Derby haha.

 

[dann2707]

No prob.
I'm in Belper mate. Think that's the first time I've heard anything remotely positive about Derby haha.

No way, me too. You'll have to come over for a brew and a nosy one night this week if you're free?

 

[rainbird]

 

[Jamess182]

No way, me too. You'll have to come over for a brew and a nosy one night this week if you're free?

Yes mate, will drop ya a pm.