Build progress - Page 6

Patrick · #**101** 8th August 2006, 19:04

Here's a sound clip of the engine, only the center resonator and original manifold: http://www.msportster.co.uk/exhaust.mp3

Patrick · #**102** 13th August 2006, 18:40

Yesterday we changed the old gearbox mounts with new ones and fitted the battery clamps.

Today it was time for some body work:

Rear wing fitment - nothing quite seems to line up anywhere on the rear tub so its not bolted down yet. Still need to spend some time jiggling it about.

Wing/door fitment. The space between the wing and the chassis is quite big so we'll need to do a bit more jiggling.

Striker pin stickout out the body work. Probably going to add a washer to move it a tiny bit further out. The body work will need bolting down here too.

Striker pin and body fitment this still needs work.

It really is starting to look like a proper car!

Patrick · #**103** 14th August 2006, 19:45

Back boxes are here!

Too much?

Nah!

peterux · #**104** 14th August 2006, 22:21

OK, so now i'm really jealous!

Very cool Mr Short.

Patrick · #**105** 25th August 2006, 18:58

Exhaust parts arrived today from Jetex. I ordered them yesterday morning!

peterux · #**106** 26th August 2006, 16:51

Patrick,
I have been having the same thoughts after seeing a post on John's SVA section above. I'm thinking of mounting a galvinised heat shield above the exhaust boxes mounted about 10mm from the box and another 10mm from the fuel tank.

I have had a look at the old SVA manual and all I can find is a statement that fuel system 'components should be mounted to avoid the risk of fire in the event of a fuel leak.

The light blue Sportster at Stoneleigh (S683 AWP) has an under floor system and I think passed it's SVA this year. Does anyone know the owner? Perhaps we could get some photo's?

Any other ideas?

Peter

Patrick · #**107** 26th August 2006, 19:02

I was looking at leaving 2 - 4 cm space between the boxes and the tank with perforated ali + heat mats.

There's a bunch of pictures of the blue sportster on our site: http://www.msportster.co.uk/detail.asp?cat=12&offset=48

It looks like its using an E46 M3 rear box very close to the ground. My plan was to have the boxes and the tank much higher up.

peterux · #**108** 27th August 2006, 21:33

Yes, that's the one. The boxes certainly look very low?

If you raise the tank higher, does the fuel filler neck hit the rear GRP bodywork?

My fuel tank came with a very short piece of filler connecting hose, so I assume that there is not a lot of space?

My Rover 75 uses that perforated ali stuff all over the place underneath but I think it is expensve? Nice and light though and I expect the SVA man would be pleased.

Peter

EddyP · #**109** 28th August 2006, 07:55

Quote:

Originally Posted by peterux

My Rover 75 uses that perforated ali stuff all over the place underneath but I think it is expensve? Nice and light though and I expect the SVA man would be pleased.

Peter

There's a cheap source of it right there then

go get under some 75s in the breakers Patrick.

Patrick · #**110** 28th August 2006, 08:30

Quote:

Originally Posted by peterux

Yes, that's the one. The boxes certainly look very low?

If you raise the tank higher, does the fuel filler neck hit the rear GRP bodywork?

My fuel tank came with a very short piece of filler connecting hose, so I assume that there is not a lot of space?

My Rover 75 uses that perforated ali stuff all over the place underneath but I think it is expensve? Nice and light though and I expect the SVA man would be pleased.

Peter

Yep the boxes are very low, there cant be more than 5 cm ground clearance - i hope he has no speed bumps where he lives!!

Not tested filler height yet, but I did run into an issue - if you put the tank too high the seat belts rest on it - not good. If you have an incident it woud dent the tank and make the belts slack. I think I've found a good compromise hight where the seat belts dont get in the way, but you still get a good 8-10cm between the boxes and the tank (with out the boxes looking too silly). I'll post some pictures later on the progress.

My E46 uses those metal things too, so there should be a decent supply in most scrap yards

- good tip Eddy thanks

Patrick · #**111** 28th August 2006, 17:26

Been busy working on moving the tank up to make more room for the exhaust boxes. A few issues, go too high and the tank gets in the way of the seat belts, same with the filler. I think it should just work in the current position. The tank need to be moved forwards a bit too so I've trimmed a little off the diff bracket - the shouldn't have any effect on the strenght of this bit as its braced further down.

Just enough room here for the belt - its a bit slack and low in this pic

Lots of room

Rear ARB in place using BMW E36 Compact ARB links

Patrick · #**112** 30th August 2006, 21:06

Spent a little bit of time in the garage tonight. Chopping the center resonator out of the old two piece exhaust. This is where the 6 branch will connect when I get it. Everything seems to be slowly coming together. The passenger side is too far to the outside of the car with the full 1meter pipe length between the two 30 degree bends. Will shorten this so that its the right size.

Noise wise, will have to see what its like, but Jetex sell DB plugs that can go in the long pipes that should quieten it down a bit if needed.

Patrick · #**113** 12th September 2006, 21:47

Sorry its been a bit quiet lately, I've just become a home owners for the first time which has completely eaten up all my time (and budget!)

That and Richards away on holiday! Watch this space for an update on the exhaust at some point soon

peterux · #**114** 14th September 2006, 17:16

Oh Patrick,
that's a disaster! You should have finished the car first!

Now you'll be like the rest of us with our "Honey do" lists...........

In sympathy. . . . . .

Patrick · #**115** 14th September 2006, 20:09

Quote:

Originally Posted by peterux

Oh Patrick,
that's a disaster! You should have finished the car first!

Now you'll be like the rest of us with our "Honey do" lists...........

In sympathy. . . . . .

I bought most of the bits I need (I hope) and there's a bit of cash left over for small things and paint

Fortunatly I dont have a "honey do" list at present

I wasnt seriously looking for house but, this one kinda came a long and I couldnt pass it up!

Patrick · #**116** 23rd September 2006, 23:04

BTB 6 Branch is here!

Its absolutely stunning!

And on the car:

EddyP · #**117** 24th September 2006, 07:24

loooking good Patrick, what you got left to do now?
you booked the sva yet? its still about a month wait around here for them.

peterux · #**118** 24th September 2006, 07:57

Looks superb!

Patrick · #**119** 8th October 2006, 19:05

Its been a while since the last up date, other things having gotten in the way of spending time working on the car!

Work continues on the exhaust system:

And thanks to Ziggy on E30Zone we now have a spare TSW BSS style alloy to use as a spare:

Patrick · #**120** 9th October 2006, 20:45

Probably not the best way to join exhaust pipes but this what we have so it will have to do! Anyway this is how the backboxes will join to the rest of the system at a different height

Another view of the exhaust construct

After some careful taping up this will have to be held under the car again to see how it all fits around the rear axels.