Blue Thing: The Daily / Motorkhana Hack (Now Efi)

[altezzaclub]

Nice engineering- that inlet manifold is a work of art!

 

I'm dying to see how it goes and what you do to tune the carbs.

[20v4agteEL31]

so much awesome man. want updates stat.

[carbonboy]

NICE! You have tons of room around that engine... for now.

 

Cheers man, funny you should say that... ;)

 

Nice engineering- that inlet manifold is a work of art!

 

I'm dying to see how it goes and what you do to tune the carbs.

 

Thankyou mate, I'm just hoping it works & doesn't fall apart in 6 months time! Tuning so far has just been changing the jet sizes (really need to get myself an O2 wideband setup ASAP) & adjusting the throttle butterfly's so that they all open the same amount at the same time.

 

so much awesome man. want updates stat.

 

Started to bolt parts up, the driveshafts were connected first, then the alternator setup. Had some fear about it fouling on the chassis/steering rack/column but all is good. Then fitted the heat-shield equipped 2A-C starter motor, then went to fit the exhaust manifold.....this is where the fun started. With the 2A-C starter, the 20v headers do not fit, the pipe from cylinder 1 hits the starter where it comes across to merge with the pipe from cylinder 4. Okay, fine, 'borrowed' the starter motor from Sudi & while the 20v headers do fit, damn they're close! :blinks:

 

Refitted the 2A-C starter & grabbed an old set of 16v factory headers, yep, it all fits but damn they're heavy & butt-ugly. I also have a set of headers with the same ID as the 20v item, similar design & clear the 2A-C starter, but it is one piece from the head to the catalytic converter & an absolute PITA to fit/remove.

 

So, while I figure out what the heck I'm going to do exactly, here's Part 1 of the video clip I've been gradually putting together. Almost as much work as the engine itself! :laff:

 

Edited January 11, 2014 by carbonboy

[carbonboy]

Starting to resemble a functional engine bay.

 

 

I always knew clearance would be tight...they fit, that's all that matters!

 

 

Aside from the clutch master, all good.

 

 

Again, I knew this would happen. I can live with it. The 'trumpets' are still a good 40-50mm from the clutch master.

 

[B.L.Z.BUB]

How will you get clean air to them? Mad hectic bonnet scoop?

[carbonboy]

For now to get it all running, just going to leave it as is. Afterwards I'm thinking about enclosing the filters with some sheet aluminium/similar & running some generic black Ebay style air-duct from the bottom of that to near the fuse-box area. Will have to 'squish' both filters a little, but it could be worse.

[carbonboy]

Slight revision of the vacuum line for the brake booster, instead of the steel tube running horizontally along the firewall to a single intake runner...

 

 

It now runs vertically along the firewall with a little 'custom' bending to suit, managed to use one of the steering rack shield bolts to mount it. It then connects to the distribution block, which has a line to all four intake runners.

 

 

Also got the ignition coil mounted, that was a bigger drama than anticipated. Now working on getting the fuel regulator mounted somewhere where it doesn't stick out like the proverbial dogs balls. Once that's in, finish off the fuel pump setup & then it's time for wiring... :blinks: ..... Bugger.

[B.L.Z.BUB]

YAY wiring! I'm glad all my next mods are basically bolt ons :)

[azza91]

how this has progressed!! looks so good in BT's engine bay.

[carbonboy]

YAY wiring! I'm glad all my next mods are basically bolt ons :)

 

Thankfully, I've managed to learn enough about what I need to do so that the bulk of the work is going to be pulling apart/replacing the interior to run/conceal said wiring.

 

how this has progressed!! looks so good in BT's engine bay.

 

Slowly but surely. It still looks a little weird to me (not just because I only saw it on a stand for months), I mean, look at the rest of the car... :lol:

 

For the environmentally concerned, I am making an effort to keep/modify/use the equivalent of the factory emissions/pollution gear. The 2A-C had a breather from the cam-cover & a vent line from the charcoal canister (c/c)to the air filter housing & a line from the carburetor to the c/c. The rest of the standard vacuum lines are for distributor timing advance & other things I've gotten rid of. Running the lines from the carburetors to the c/c is pretty simple, the vent line from it & the cam-cover vent that are meant to go to an air filter housing are a little trickier. If I can dig out a catch-can I have somewhere, may even use that.

[carbonboy]

Forty-plus degree days suck for working on cars, thankfully I was in the shade underneath finishing the fuel pump setup. Made brackets from 3mm plate steel & used existing fuel tank strap mounting points.

 

 

Used a spotlight mounting bracket I bought twelve years ago but never actually fitted as a mounting bracket for fuel pump. Pump is mounted on rubber bushes so that vibration doesn't kill it or transfer to the vehicle body. Sounds good in theory I guess.

 

 

Connected hoses & earth wire.

 

 

All mounted.

 

 

From tank/inlet side.

 

 

To engine bay/outlet side.

 

 

Sits pretty flush with the tank, hopefully will act as a protective cover for the pump too.

 

 

 

Seats, centre console & dash are all stripped out ready for wiring fun-times. Had plans on starting tonight, but thinking cold shower, dinner & bed is the go. Crawled in & out from under the car more times today than I care to think about.

Edited January 14, 2014 by carbonboy

[carbonboy]

Spent most of today A ) Trying not to melt & B ) Getting my head around wiring. I'm horrible at it, not horrible as in dangerous/set things on fire, I just get confused easily. Wiring diagrams are cool & all, but it only all really makes sense when laid out in front of me. No fancy hidden wiring here, just keeping what I have & need, adding what I need & don't have & removing what I don't need. Then just fresh conduit & tape, make it neat.

 

[B.L.Z.BUB]

What helped me was drawing my own diagrams. It can get confusing looking at a factory diagram, especially if its on multiple pages. I took all the single circuits I needed to wire and drew them out individually. Not only was it easier to read but it also helped my brain sort it out.

Edited January 15, 2014 by B.L.Z.BUB

[carbonboy]

Got my head around the circuits, most of them anyway. Struggling with the distributor pickup wiring & the heat to be honest.

 

[carbonboy]

Progress has been happening, slowly. Wiring is 95% completed, then testing to make sure my switched 12v etc are correct, then wrapped back up in conduit. Had a small hold up with working out how exactly to wire the MSD to the distributor, a few back & forth emails to their help-centre later all was sorted. Have to say that they were most helpful, despite being on the other side of the world.

 

Also made headway into retaining the emissions systems, albeit modified. It's hard to take photos to show what I've done, so my dodgy Paint picture will have to do. The purge line from charcoal canister that normally goes to the throttle body is now teed into the PCV feed to the catch can, then all that vapour goes to the intake plate (the black plastic thing the trumpet screw to). On the other side of the intake plate, I have a hose with a tee piece to run the vapours between each pair of trumpets where I'm hoping it gets sucked in. Will have to keep an eye on how dirty the filters get/how quickly.

 

 

The catch can is mounted next to the vacuum canister, up underneath the intake manifold, was a pain to fit but won't attract attention. It's also stuffed with stainless steel scourers to act as a 'scrubbing medium' to help seperate the oil from the vapour. There's no return line to the sump on the oil catch can at the moment, have the fittings etc, just want to see how much builds up & see if it's a need.

 

 

Engine bay is coming up nice & subtle, the only thing you can easily spot is the pressure gauge on the fuel pressure regulator.