mk1 valver rally car

[wookie]

Im not dead honest.....

Been stupid busy recently and the weather doesnt help as the car is outside
But got alittle done yesturday afternoon....,the injectors are in, fuel rail etc (2nd time as i broke one lol) and started sorting out the engine wiring loom, which started to really pi55 me off as i hate wiring, so dads doing that tomorrow and i went back to what i enjoy, making crap!

When i got my emerald ecu, the feet were missing, and dave walker doesnt sell them seperatly, so i made a 'cradle' for it out of some alloy sheet i had laying around, then had to make a 'side' for my centre console so i could mount the ecu there, which is nice and out of the way but easy to get to the comms port for mapping etc.

Started off with this after removing the co drivers footrest to give me alittle room to get my arms in

And finished with

Not super neat but it will do, then i needed to make the hole in the bulkhead that my loom plug will mount into

That was dead easy as theres acers of room in the bay now, and all the loom is routed and cut to length, just need to make up the plugs which is tomorrow nights job then re-fit it once its made

It was very dark by this point, not to mention cold even with my generous layer of 'insulation' so thought id best weld something.....,ah the cardboard templates id made for an airbox/heat shield were still laying on the dash, so out came the welder and a sheet of 20swg steel and had a play

All cut and taked in place

Removed it, welded it up and re-fitted to check it hadnt warped, which it hadnt which was nice, and there it is ready for a coat of paint

It isnt perfect, but should stop hot air from going directly into the filter after passing through the rad, plus there will be a line of holes at the back of the bonnet to try and aid the air flow through the engine bay. The inlet air temp sensor is being used with the ecu so we can monitor the inlet temps anyway, if they are still too high then ill come up with a better solution at a later date.

And as always sorry about pic quality, using my phone in the dark

cheers

 

[Riad]

Nice update, Just read it all looks awesome!

 

[AdamAnderton]

Some nice progress being made here
You still want the manifold

 

[wookie]

Yes i do, just read your pm, im so crap with them!! ill pm you my email in a sec so you can send me a paypal invoice.

 

[Nickharding]

Very cool!

 

[jamie rigby]

coming on well! but... what about engine bay and maniflod temps. still gonna get sucked in isnt it!?...

 

[wookie]

to a certain extent yes, but with a shield it will stop the hot air coming through the rad going directly into the filter, and with some holes at the back of the bonnet the flow of air through the engine bay should be improved, plus im looking at where to put a cold air feed to it, basicaly what im doing is trying to improve it for free, if i fail then ill either make or buy an airbox, but yes i understand where your coming from.

I was going to have a feed from one of the ducts in the front bumper i have fitted, but decided that in the bumper it is too low, as some events we do have quite deep water or even fords to cross, and dont want a jet of water being fired at the filter, so thinking of some sort of vent let into the bonnet on that side, like a nascar vent maybe, but we will see, ill think of something lol.

 

[wookie]

Well what a fun evening i have had...,not! lol. I hate wiring, always have and always will, but had to start the wiring for the ecu at some point, so here we have.....,the kitchen table

What a joy full sight....,hmmmm...,anyway, my hands are definatly not the right size for wiring ecu plugs etc, stupid little green christmas tree seals and tiny crimp connections, i work on buses, i like big stuff!

But after a few hours of fighting with things i can hardly hold, i have an interior loom from the ecu to the bulkhead plug all ready to fit.

The big bunch of yellow under the braid is a label on each wire so i can hopefully follow what im doing

Also ran 9 spare wires through the plug just incase i need anything else to pass through the bulkhead, just to make it easier if that happens at a later date

With the matching colours etc on the engine side

Obviously they are only resting in the correct holes till i make up that side of the plug, but its good progress and i think its neat enough compared to the original french wiring:dead:

 

[jamie rigby]

very tidy!

 

[2 live]

just read all the thread. good work fella is comin on really well.

 

[Whiteley]

We use those bulkhead plugs at work... I hate doing them!

 

[wookie]

Damm its cold working outside in the evenings!

Got alittle more done, very close to firing it up now ready for mapping.

Finished the engine loom finaly, if i never see another wire again ill be happy,altho gota do it all again with my escort at some point:dead: but it has turned out reasonably neatly.

Also had a big box arrive today....,with this inside it, sure some members will recognize it....

Huge thanks to adam, damm good lad i reakon:star:

Going to re-rap it with new wrap then chuck it on, far too wet and cold this evening!!

Then i did stage 2 of sorting cold airflow to the filter after i changed my mind on the previous idea due to the water we potenialy get on events, so can anyone guess where this came from?

Yep you got it

Ready for....

And finished with

And last pic you can see with a 90 degree bend on the end, will direct cold air straight onto the filter (which you cant see due to the airbox/shield/black thing

I had to have a vent/duct that went in rather than out as for road rally rules you cant change the silluette of the car, which this doesnt, and unfortunatly the road rally rules are also what is stopping me from having a fibreglass bonnet as they arent allowed, would be fine if i was only using it for stage rallys but as im doing both i have to adhere to both sets of rules

Anyway i have an event on the 22nd of jan so it has to be up and running, mapped, mot'd and new brakes bed in etc by then, so looking forward to it

And as always sorry for shocking picture quality, phone camara at night isnt a good mix!!

Cheers

 

[DannoTheGreat]

good work fella fair play

 

[AdamAnderton]

Looks all neat and tidy mate, good job

Glad you got the manifold ok sorry about the wrap

 

[AdamAnderton]

Wot is the black stuff over the wires and were did you get it from

 

[Whiteley]

You've made a good job of that loom, top marks. Let's hope you manage to bolt the manifold on better than the previous owner, hey Adam

 

[AdamAnderton]

yes ok thanks

i was pretty useless at it

 

[jamie rigby]

should see some decent flames with that manifold on

great work as per!!

 

[clvs2222]

you mentioned about water gettin in, how will you stop water gong through the funnel straight into the filter and into the engine?

 

[aliengravy]

A Rain catcher!! COOOOL

 

[AdamAnderton]

Give the man chance to say if its finished or not

still looks to me as the car is not quite finished yet

 

[wookie]

It is only to direct cold air in, it isnt plummed straight into the inlet, the trunking i have in convoluted (spelling) so any water going in will only drip out of the end, there will be a good 4 inches between the end of the duct and the filter itself. That is what i am hoping will stop any water ingress anyway, time will tell, the filter on our red 205 sticks out of the bonnet due to the angle of the jenveys and doesnt cause a problem on wet stages, so fingers crossed.

Please excuse the angry weetabix, he gets bloody everywhere!!

The black stuff the loom runs in is nylon over-braid, i got it from my navigator as he makes looms for a living...,he hasnt seen mine yet so hopefully he will approve lol, i assume you can get it from any electrical supplier, altho i never tried as raa got it for me.

And no worries about the wrap, if the manifolds removed and re-fitted a couple of times it doesnt take long before it gets biff, we have wrapped the red 205's manifold about 5 times now and its rather alot bigger than the clio one

Im not sure i like the pinch bolt method of joining the secondaries, i may remake them, ill see how it goes together 1st tho.

 

[Jonny1*2]

nice work mate. great read. keep it up :approve: