2 litre 8v Turbo

[MattG]

Some good updates , save reading all pages (allthough still worth reading all the pages !! ):

spec :

2 litre 8v vauxhall engine out of a cav sri
T3 Carrot Turbo on homemade log manifold
Home Made Megasquirt ECU ( running std vauxhall crank sensor ) running wasted spark
5 link allspeed rear beam floating rear axle.
Roll cage.
custom allspeed front subframe to allow for 3 inch down pipe

3" Stainless exhaust system
Custom inlet manifold running 2.5 v6 TB
In car computer running Linux ( ubuntu ) also runs tunerstudio , gps , wifi etc


this is it now reving up ... sounding a bit less like a tractor !!

http://www.youtube.com/watch?v=0Rx2vT0pVY8

and this is from the exhaust end :)

http://www.youtube.com/watch?v=Got92ftT6I4 (http://www.youtube.com/watch?v=Got92ftT6I4)

video of dash lightup :

http://www.youtube.com/watch?v=xpbPDsI2khM

video of first test drives :

http://www.youtube.com/watch?v=xc6Ib4EwVOo

http://www.youtube.com/watch?v=ElRR1SxhkcQ

flames popping

http://www.youtube.com/watch?v=kWZSf6vEhUs

[Andy_S]

:lol:

[Geehawk]

Dont forget you have to have it finished for L2B :shock: :lol:

[Hayling mini]

Good luck Matt, dont forget the sign on the drivers door "Please pass on this side" :lol:

[Joah]

ooooo the suspense... :lol:

[Hayling mini]

Were are the pics Matt?

Thought you were starting it yesterday :D

[Allan McD]

I am so exited I can hardly contain myself :lol:
Allan

[Marcus Nordblom]

His maybe down southern france on a maiden voyage/shakedown :lol: :lol: :lol:

[Hayling mini]

He is in Yorkshire & I have a feeling this will be a very quick conversion. He is the tick tack man & works at 300mph :lol:

[Welder]

This Dutchman does not understand wat is happening.... What is the plan?

:?:

[PaulW]

This Dutchman does not understand wat is happening.... What is the plan?

:?:

dont worry dude non of do?

[MattG]

pics soon lads .. its wet outside .. but the engine is out of the donor car ...

Matt

[Hayling mini]

Matt started this forum & has done loads & I mean loads of conversions, Vauxhall 1.6 8V, 1.6 16v, 2.0 16V, V6. Numerous Vtec including Type R in standard roundnose, various Rover. Suzuki GTI, I am sure some have been missed.
He has also helped so many people on here with help & advice, without him I for one would not have completed my first one. 18 months after joining this club I am on my 3rd & I owe a hell of a lot to Matt.
He has not done a conversion for himself in a long time, so this is a much awaited project.

Jerry

[MattG]

Ok guys , its been a long time since i have done a project myself .. been helping others / real life / Mum (RIP) etc etc ..

so .. after much dreaming about what to do i ended up with the 2 litre 8v vauxhall engine , a turbo will be added to this to push up the bhp.

First was the use of my sisters old cav sri ... :

http://www.teamorchard.co.uk/wp-content/uploads/2009/02/dscf1607.jpg

Engine was removed today :

http://www.teamorchard.co.uk/wp-content/uploads/2009/02/dscf1609.jpg

This will all be going into a clubman that my dad had laying around , pretty solid and will just need some sills (so my dad says)

I am aim to do some sprints this year , so a roll cage was needed

http://www.teamorchard.co.uk/wp-content/uploads/2009/02/rollcage.jpg

some wheels

http://www.teamorchard.co.uk/wp-content/uploads/2009/02/dscf1590-medium.jpg

[MattG]

ok , have been thinking turbo for awhile , and have looked at lots of vauxhall engines in allspeed subframes ...

One of my problems in using a std allspeed subframe was room for the turbo down pipe ( 3 inch) , especially down below the sump.

so I ordered a custom subframe which had a VTEC tie bar setup on it , anyone that knows subframes will spot the difference :

http://www.teamorchard.co.uk/wp-content/uploads/2009/02/subframe1.jpg

This picture shows my extra room :

http://www.teamorchard.co.uk/wp-content/uploads/2009/02/frame4.jpg

Ok i am still learning about turbos .. so i am sure i will buy / make lots of wrong things .. but thats half the fun ! lol

picked up a cast turbo manifold ( thanks rich) but arrived broken . might not use it anyway as its for a T25 , waiting on laser cutters to make me a flange , and might have a go at making a new manifold

http://www.teamorchard.co.uk/wp-content/uploads/2009/02/dscf1592.jpg




I will be running a F18W with hydro clutch

Turbo , set at 8psi as standard , but will go to 25psi :

http://www.teamorchard.co.uk/wp-content/uploads/2009/02/dscf1595.jpg

[Allan McD]

I hope when you say sprints you mean hillclimbs as well they are far more exiting :D
Allan

[MattG]

Intercooler , will fit just behind the grill :

http://www.teamorchard.co.uk/wp-content/uploads/2009/02/dscf1600.jpg

and some pipe work :

http://www.teamorchard.co.uk/wp-content/uploads/2009/02/dscf1601.jpg

picked up a dump valve the other day as well .. just looking for a good Air filter setup

well , that's most of my photos for now , will get some of the mini tomorrow (but looks like most minis )

should start on welding of the mini next week, and get the cage in ...

lots to do , happy to take advice from expert forum members .. but please don't be surprised if i ignore the advice as what would you know :wink:

[MattG]

I hope when you say sprints you mean hillclimbs as well they are far more exiting :D
Allan

i will do anything the let me do LOL ..

might even drive it to work

Matt

[Andy_S]

8) COOOOOOL 8)

Welcome back to the fun (& wallet emptying) side of valver conversions. :D

[*franky*]

will be watching this one. would love a turbo on mine lol. gud luk

[MattG]

split engine from gearbox , as i have a f18WR waiting ...

will strip mini tomorrow and load up ready to bring home.

Matt

[MattG]

ok , dug the clubman out today , needed 4 wheels changing as they had been flat for 4 years , and would not stay up ... but once done i pushed it out :

http://www.teamorchard.co.uk/wp-content/uploads/2009/02/dscf1614.jpg

pulled the seats out , and got it up onto the trailer ready for the trip home :

http://www.teamorchard.co.uk/wp-content/uploads/2009/02/dscf1616.jpg

looks like it will just need sills ,and maybe a few small things ...

http://www.teamorchard.co.uk/wp-content/uploads/2009/02/dscf1617.jpg

http://www.teamorchard.co.uk/wp-content/uploads/2009/02/dscf1619.jpg

rear area looks good :

http://www.teamorchard.co.uk/wp-content/uploads/2009/02/dscf1620.jpg

no rust in boot either..

loaded it up with all the spares and vauxhall engine was put where the passenger seat was :)

old cav was taken away by the scrap man in the afternoon.

now a 250 mile drive back home on friday to unload.

Matt

[MattG]

ok , 4 1/2 hours later it's back home in my garage ...

have to go help a good friend tommorow with his mini , so wont touch it untill sunday...

Matt

[Phaeton]

250 miles in 4.5 hours with the state of UK roads is good going not taking into account pulling a twin axle a trailer.

Alan...

[Allan McD]

It may be the quickest that we mini ever goes :lol: :lol:
Allan

[Cheeky Little Monster]

I have just fallen in Love........... with your wheels.........they are very cool.....but I hate you because I was so not looking for a set of new rims!!!!!!.........but I have fallen in love :)

[MattG]

spent some time today , should have been more but slept in .. must stop that
Started by stripping some bits and bobs , remove passenger door and removed cav engine , :
http://www.teamorchard.co.uk/wp-content/uploads/2009/02/dscf1627.jpg

roughly cut out rear pockets and base of rear seat :

http://www.teamorchard.co.uk/wp-content/uploads/2009/02/dscf1625.jpg

http://www.teamorchard.co.uk/wp-content/uploads/2009/02/dscf1626.jpg

then trial fitted the roll cage to see whats what ..

http://www.teamorchard.co.uk/wp-content/uploads/2009/02/dscf1630.jpg

http://www.teamorchard.co.uk/wp-content/uploads/2009/02/dscf1631.jpg

and a few better pics of the subframe

http://www.teamorchard.co.uk/wp-content/uploads/2009/02/dscf1632.jpg

http://www.teamorchard.co.uk/wp-content/uploads/2009/02/dscf1633.jpg

need to source some front disk hub setup next..

Matt

[MattG]

got all but one of the exhaust studs out , and that snapped into the head ! :twisted: . remember to allways use some heat on all of them .. regardless of how easy they come out

http://www.teamorchard.co.uk/wp-content/uploads/2009/02/dscf1634.jpg

ripped old mini tank out , and chucked in a smaller tank i picked up of ebay , it will do for now , and has connections for a return for the injection pump

http://www.teamorchard.co.uk/wp-content/uploads/2009/02/dscf1635.jpg

stripped the head lining , removed the rest of the window , removed front subframe bolts so thats ready to be dropped out now .

need to pick up some zink primer and get a coat on the subframe before that goes in.

ordered a quick release steering boss , some fuel pipe and some bump stops.

also got a trick rear suspension setup on its way :)

Matt

[MattG]

did a bit last night , removed internal heater , put some etch primer on subframe.

undone all bolts to remove front subframe , just need to remove shocks.

Tried removing the drivers door , but then found that the nuts had dissolved :evil: , so as the a-panel has to come of i will have to do that tonight and then cut through the hinge studs :twisted:

quick release boss turned up , so will look at fitting that as well.

Wife is going out shopping Sunday for the day , so should get a good bash at it.

Matt

[MattG]

ok , front subframe is out , found more rust when i cut the drivers side a-panel off , i did this so i could grind the nuts off the door hinge ....

must have a word with my dad "a few sills son" :lol: cant grumble .. i got the car for free.

once subframe was out the way , i welded in the bulkhead box , and gave it a spray of etch primer.

tacked in to start with :

http://www.teamorchard.co.uk/wp-content/uploads/2009/02/dscf1636.jpg

then painted :

http://www.teamorchard.co.uk/wp-content/uploads/2009/02/dscf1638.jpg

as i keep jumping from job to job , i got the quick release steering wheel adaptor welded to the end of the Corsa EPS coloumn :

http://www.teamorchard.co.uk/wp-content/uploads/2009/02/dscf1639.jpg

and tested the steering wheel on it , a small bit of play in the quick release , will have a look at that another time :

http://www.teamorchard.co.uk/wp-content/uploads/2009/02/dscf1640.jpg

gave the subframe a coat of etch primer as well :

http://www.teamorchard.co.uk/wp-content/uploads/2009/02/dscf1641.jpg

stripped old front subframe of parts , will be running rubber up front ..

http://www.teamorchard.co.uk/wp-content/uploads/2009/02/dscf1642.jpg

tommorows jobs are to trim inner wings (done one) and fit the subframe ready to drop engine in. Will also get some 2mm sheet for the spreader plates for the rear subframe mounts.

[Allan McD]

found more rust
Thats a first on a mini :lol:
Allan

[cooper_mark]

frame's looking sweet matt...what etch primer did u use in the end.....?
was it spayed or brush on....??
as u say FOUND MORE RUST...that mini's for ya more rust.....rust....rust.... :wink:

[DarrenW]

I cant believe you are putting power steering on it :shock: :shock:

Think of the extra weight man :P

What are you a big girls blouse :wink:

[Mark D]

What are you a big girls blouse

Says You!!!!

[MattG]

first fit of subframe :

http://www.teamorchard.co.uk/wp-content/uploads/2009/02/dscf1646.jpg

http://www.teamorchard.co.uk/wp-content/uploads/2009/02/dscf1647.jpg

[MattG]

collected my exhaust flange for the turbo manifold , would prefer thicker .. but it will do for now

http://www.teamorchard.co.uk/wp-content/uploads/2009/02/dscf1649.jpg

[Marcus Nordblom]

Looking good Matt, hang in there!

[MattG]

cut some 2mm plate and bent (ish) to go inside and welded to the floor where the front subframe bolts through the floor.

http://www.teamorchard.co.uk/wp-content/uploads/2009/02/dscf1650.jpg

[Hayling mini]

Looking good Matt, roll on L2B

Jerry

[evolotion]

collected my exhaust flange for the turbo manifold , would prefer thicker .. but it will do for now

http://www.teamorchard.co.uk/wp-content/uploads/2009/02/dscf1649.jpg

for the exahust matt.cut each bit seperate and bolt to a spare head without a gasket, really tight, preferably with some copper ease or something between flange and head to get heat out it after weldign quickly. then weld.

if you keep the whole thing as one, itll warp and spring when you unbolt it off the head also try weld the whole manifold all seams, then finally weld this to the flange so the rest of the manifold has "settled" first.

have had to repair a few turbo manifolds with thin flanges, and that procedure has prooved the best, assuming your welding mig like me :)

[MattG]

cheers dennis , will do ..

[tommi_balls]

how do u think the suspension geometry will be effected by moving the front tie-bar fixing points outwards as they are usually inline with the lower arm mount. im thinking as the arm rises on bumps it will increase the castor?
im in the garage as we speak making my subby and deciding the best way to make the lower arms.

[MattG]

anything you see wrong evo ? :

before i start to make a manifold

http://www.teamorchard.co.uk/wp-content/uploads/2009/03/dscf1659.jpg

http://www.teamorchard.co.uk/wp-content/uploads/2009/03/dscf1658.jpg

http://www.teamorchard.co.uk/wp-content/uploads/2009/03/dscf1660.jpg

[evolotion]

i assume your going for a log style maifold from thich steel gas pipe weldells? if so crack on :) positioning looks great for it!

[MattG]

i assume your going for a log style maifold from thich steel gas pipe weldells? if so crack on :) positioning looks great for it!

i was .. but i dont have steel gas pipe . its just normal exhaust pipe bends .. is this to thin and not worse using ?

Matt

[MattG]

bit back wards , but :

fitted the gearbox to the engine , :

my 8 year old helping me on the hoist.
http://www.teamorchard.co.uk/wp-content/uploads/2009/03/dscf1651.jpg

i modded the rear mount and added a small plate on top , this then helps the gear linakage pin stay in . just like it does on the vauxhall

http://www.teamorchard.co.uk/wp-content/uploads/2009/03/dscf1653.jpg

and my daughter checking that i had done the rear mount ok :

http://www.teamorchard.co.uk/wp-content/uploads/2009/03/dscf1654.jpg

i also welded in the 2mm floor plates inside the car.

Matt

[evolotion]

tough one matt.. but id put money on it cracking after a few months, if it hold out that long.

2 T pieces, 2 90 degree bends and an offcut of pipe like this stuff::

http://www.pipesupply.co.uk/epages/es113396.sf/en_GB/?ObjectPath=/Shops/es113396_shop/Products/1640TEES/SubProducts/1640TEES15&ChangeAction=SelectSubProduct
http://www.pipesupply.co.uk/epages/es113396.sf/en_GB/?ObjectPath=/Shops/es113396_shop/Categories/%22Steel%20Systems%22/%22Steel%20Pipe%20Fittings%22/BS1640/164090LRWES

or 3 t-pieces if you want to get fancy for the turbo outlet.

try finding a local trade plumbing / hydraulic place most will deal wit the publicand if you find the righ tplace youll get the bits and an offcut of pipe for a reasonable fee.

but up to you, given teh car wont be a daily drive it may not get enough heat cycles to start cracking, or you may find the occational weld acceptable :)

[MattG]

tough one matt.. but id put money on it cracking after a few months, if it hold out that long.

2 T pieces, 2 90 degree bends and an offcut of pipe like this stuff::

http://www.pipesupply.co.uk/epages/es113396.sf/en_GB/?ObjectPath=/Shops/es113396_shop/Products/1640TEES/SubProducts/1640TEES15&ChangeAction=SelectSubProduct
http://www.pipesupply.co.uk/epages/es113396.sf/en_GB/?ObjectPath=/Shops/es113396_shop/Categories/%22Steel%20Systems%22/%22Steel%20Pipe%20Fittings%22/BS1640/164090LRWES

or 3 t-pieces if you want to get fancy for the turbo outlet.

try finding a local trade plumbing / hydraulic place most will deal wit the publicand if you find the righ tplace youll get the bits and an offcut of pipe for a reasonable fee.

but up to you, given teh car wont be a daily drive it may not get enough heat cycles to start cracking, or you may find the occational weld acceptable :)

Ok evo , got some on order from a local supplier , they will be in tommorow , .. those T peices are costly :shock: but i supose still cheap for a manifold ... will sell my old cast one to raise funds for new one :)

Matt

[evolotion]

awesome stuff mate, keep the pics coming!

[Mark D]

I cant believe how quickly matt can put a car together. I think only allan mcd can compete with him on this score. A couple of races to do the fine tuning and i thing he will be cooking on gas!!!

[cooper_mark]

he's only bolted a rollcage subframe...and engine in couple of hours work...if the stuff is there ready..

[MattG]

I cant believe how quickly matt can put a car together. I think only allan mcd can compete with him on this score. A couple of races to do the fine tuning and i thing he will be cooking on gas!!!

shame its all got to come apart to be painted :)

and are you allowed gas ? :wink:

[MattG]

collected the pipe fittings today , just need welding together :

http://www.teamorchard.co.uk/wp-content/uploads/2009/03/dscf1662.jpg

[MattG]

ok , only got an hour tonight :

welded the two T peices together ,once i ground them a bit to match the ports :

http://www.teamorchard.co.uk/wp-content/uploads/2009/03/dscf1663.jpg

Then ground down the other side of the T to allow for one of the elbows to line up with the port :

http://www.teamorchard.co.uk/wp-content/uploads/2009/03/dscf1664.jpg

i kept seam welding each peice , so when i was finished i knew it was not going to move all over the place :

http://www.teamorchard.co.uk/wp-content/uploads/2009/03/dscf1665.jpg

http://www.teamorchard.co.uk/wp-content/uploads/2009/03/dscf1666.jpg

i have now tacked it to the flange , and tonight i will weld the T3 flange on , then the turbo should bolt up under its own weight...

[MattG]

i could not be arse to grind down all the welds .. as i thought this should be as strong as it can be .... does not need to be pretty ...

[Marcus Nordblom]

looks excellent and very strong Matt!

also thinking that that mani design will help a bit with flange warping 8)

[MattG]

ok evo , hows this looking :

crude is my middle name , tacked some strips of metal to the T3 flange :
this helps for the curve of the tube , and less "fly fishing" welding :)

http://www.teamorchard.co.uk/wp-content/uploads/2009/03/dscf1667.jpg

Then cut a small hole in the manifold to let the gasses out :) thanks for the tip alan :wink:
http://www.teamorchard.co.uk/wp-content/uploads/2009/03/dscf1668.jpg

This all the got welded together :

http://www.teamorchard.co.uk/wp-content/uploads/2009/03/dscf1669.jpg

test fit :

http://www.teamorchard.co.uk/wp-content/uploads/2009/03/dscf1672.jpg

http://www.teamorchard.co.uk/wp-content/uploads/2009/03/dscf1673.jpg
All that is left to do is weld to the exhaust flange , allthough i will be getting my friend to do this as he has a larger welder.

as i only had a few minutes left , i thought i would play with the 3 inch down pipe :
http://www.teamorchard.co.uk/wp-content/uploads/2009/03/dscf1675.jpg

http://www.teamorchard.co.uk/wp-content/uploads/2009/03/dscf1676.jpg

http://www.teamorchard.co.uk/wp-content/uploads/2009/03/dscf1677.jpg

[evolotion]

thats lovely matt :) .. you gotta admit, those bends are much nicer to make a log manifold out of than regular pipe :) love the way you did the T3 flange too. my only possible criticism would be you could have got the turbo much closer to the block giving you more room for coolers up front, but that woulda made the fitting of the turbo flange harder!

the log design looks very badly flowig to the eye, but its a well proven setup, simple and reliable :)

[MattG]

compressor is hitting the block evo :( so yea IC will stick out a little.

crude but effective ! .. cant wait ..

is there any reason why a ECU can't contoll a waste gate by using a servo ?

Matt

[XEValver]

Matt that is seriously cool!

do you know what the total depth of that setup is? from the flange face of the head to the front-most point on the turbo?

[tommi_balls]

looks good mate 8)

[evolotion]

compressor is hitting the block evo :( so yea IC will stick out a little.

crude but effective ! .. cant wait ..

is there any reason why a ECU can't contoll a waste gate by using a servo ?

Matt

apologies mate, it looks like its sitting out much further in the pics!

yes you can controll it with a servo alpa on turbominis has done this. however, the Keep It Simple Stupid rule applies again! if you loose boost controll you will kill your engine, so an actuator and a bit of carefully routed hose + whatever kind of boost controll device is all you really want ;)

proven, tried , tested, relaible.

[Allan McD]

Looking Fast it should show a few Hondas the way to go 8)
Allan

[Mark D]

and yours will go the same way as the honda, through the fence :lol: :lol:

[Owen]

and yours will go the same way as the honda, through the fence :lol: :lol:


He will get to the fence first tho :lol:

[Mark D]

He will get to the fence first tho

Thats good, i'll get through the same hole with less damage.

[MattG]

Matt that is seriously cool!

do you know what the total depth of that setup is? from the flange face of the head to the front-most point on the turbo?

will try and get a mesurement when its on next.

Matt

[2many]

Some great ideas for a compact turbo setup. I was considering a log manifold, but hadn't though of cutting the back out of the Tee piece.

Nice work!

[MattG]

this turned up this morning ....

http://www.teamorchard.co.uk/wp-content/uploads/2009/03/dscf1678.jpg

thanks allan :wink:

[Joah]

Two boxes and a Pallet? :? :wink:

[mininut]

Two boxes and a Pallet? :? :wink:


shhh, thats the flux capacitor :wink:

M.

[Andy_S]

That's gotta be Allan's old rear axle setup & a box of rear brakes .......... :wink:

[Marcus Nordblom]

or maybe some bag pipes and a case of laphroig 8)

[Andy_S]

or maybe some bag pipes and a case of laphroig 8)

Even better. :D

[MattG]

yep , its allans rear axle setup :

http://www.teamorchard.co.uk/wp-content/uploads/2009/03/dscf1679.jpg

going to take more than one evening to fit this ...(alan , could not find the instructions in the box :| :wink: )

ripped rear subframe out :

http://www.teamorchard.co.uk/wp-content/uploads/2009/03/dscf1680.jpg

started cleaning the beam up , will fit the boxes inside the car first , then turret the archs .. and then see if it fits :)

Matt

[Andy_S]

Hey Matt,

If you get chance, could you do me a favour & weigh the axle with/without the brakes. Mark D has been insulting my homebrew rear axle (cos he's mean :( ) & I'd just like to compare it with a professionally made piece of kit.

Many thanks



Andy
___________

[bhphunter]

So has Alan stripped his Vauxhall racer and built the Hayabusa one from the shell?

I thought he built that from a spare shell :?



Loving this project Matt 8)

[MattG]

ok , got one tacked into position

http://www.teamorchard.co.uk/wp-content/uploads/2009/03/dscf1681.jpg

and got the other roughly positioned , just need to cut hole in floor and tidy up pocket area.

http://www.teamorchard.co.uk/wp-content/uploads/2009/03/dscf1682.jpg

[Allan McD]

I built my new car from a spare shell and I am breaking the old racer.
Maybe I should have sold the car compleate as a CHAMPIONSHIP winner :lol: for £20 or £30 grand :wink: but I didnt think I could find anyone stupid enough :shock:
Allan

[MattG]

I built my new car from a spare shell and I am breaking the old racer.
Maybe I should have sold the car compleate as a CHAMPIONSHIP winner :lol: for £20 or £30 grand :wink: but I didnt think I could find anyone stupid enough :shock:
Allan

well at least the back end of the car might win somthing :shock:

[Allan McD]

I thought you (Matt) had a job :?:
You seem to have done too much today for some one with a full time job did you take a sicky :?:
Allan

[Hayling mini]

In the south due to new health & safety policies all employees have to take a mandatory 6 hour lunch break.
It is a new EU directive, work from home on a friday, get up at 9.30, log onto your computer with your dressing gown on whilst scratching your left testy. Send a couple of emails about nothing, but lets the boss know you are working.
Breakfast & dressing period runs between 9.30 & 11.15. Do some research until 12.00, updating web sites, send a couple more irrelevant emails & maybe phone a couple of people in the office about anything that comes to mind. Make a point of telling your boss how hard you have been working all day & explain that you would rather not have too many calls in the afternoon due to the amount of paperwork you need to do.
1.15 go out into the garage & work on the Mini, pop in every hour to send more irrelevant emails & maybe make a call.

Have they not rolled out this scheme in the north yet :D

[MattG]

not as much time as i would have liked on the car today , but got my 8 year old to clean up the steering rack , and spray some paint onto it.
fitted new boots and have some new track rod ends to go onto it. :

http://www.teamorchard.co.uk/wp-content/uploads/2009/03/dscf1686.jpg

got the other beam support box tacked into place :

http://www.teamorchard.co.uk/wp-content/uploads/2009/03/dscf1688.jpg

and then had to cut the boot floor out ! , scrap mans going to be happy tommorow :

http://www.teamorchard.co.uk/wp-content/uploads/2009/03/dscf1687.jpg

Last thing i did was bolt up the rear beam to the link rods to see whats what ... got to turret and tub the arches next :

http://www.teamorchard.co.uk/wp-content/uploads/2009/03/dscf1689.jpg

[PaulW]

fuck me i'm too busy at the moment to take photo's :D Looking good Matt can't wait to see it live.

Paul

[MattG]

started cleaning up and painting the front hubs , got to do top arms as well yet.

just drilled the top of the rear towers to bolt the rear shocks to .. just need to get them tacked into position now :shock:

http://www.teamorchard.co.uk/wp-content/uploads/2009/03/dscf1691.jpg

[Allan McD]

Those shocks look expensive I bet they cost me more than I remember :cry:
Allan

[MattG]

Those shocks look expensive I bet they cost me more than I remember :cry:
Allan

not touching the settings on them :lol:

[MattG]

not getting much done at all ...

popped round my mates (thanks Jim) who tigged up the manifold :

http://www.teamorchard.co.uk/wp-content/uploads/2009/03/dscf1695.jpg

and the down pipe to the clamp ring :

http://www.teamorchard.co.uk/wp-content/uploads/2009/03/dscf1694.jpg

all done , maybe some high temp paint to make it look better .. but sure that will burn off LOL

http://www.teamorchard.co.uk/wp-content/uploads/2009/03/dscf1696.jpg

got a some metal to make a new slam panel , this will help with IC clearance. need to find a honda rad i think , as that will fit nice.

picked up a small alternator as well , but will make a bracket for that once the engine is back out.

cleaned up the 2nd hub and slapped some paint on it ..

if i dont get this back on 4 wheels next week i am behind !! :)

Matt

[*franky*]

lookin good matt. question tho what kind of ecu you going to be using also are you using the standard inlet

keep up the gud work looks live its going to be one hell of an animal :twisted: :twisted:

[MattG]

lookin good matt. question tho what kind of ecu you going to be using also are you using the standard inlet

keep up the gud work looks live its going to be one hell of an animal :twisted: :twisted:

it will be :megasquirt: , and will run the std inlet

and thanks i hope so...

Matt

[MattG]

ok , started tubbing the arches today , first marked out and cut the wing :

http://www.teamorchard.co.uk/wp-content/uploads/2009/03/dscf1697.jpg

then then cut slits and bent upwards , then used the spot welder to join back up ...

http://www.teamorchard.co.uk/wp-content/uploads/2009/03/dscf1698.jpg

completed arch (apart from mig welding :)

http://www.teamorchard.co.uk/wp-content/uploads/2009/03/dscf1700.jpg

just got to buzz over the gaps with the mig welder :

http://www.teamorchard.co.uk/wp-content/uploads/2009/03/dscf1701.jpg

drivers side done as well

http://www.teamorchard.co.uk/wp-content/uploads/2009/03/dscf1702.jpg

fitted rear wheels to set the turret height , which is next to do :

http://www.teamorchard.co.uk/wp-content/uploads/2009/03/dscf1703.jpg

rear beam hits whats left of old boot floor , so disk cutter back out tommorow.

[Marcus Nordblom]

Looks tidy Matt 8) Isn´t it a bitch to weld upwards when filling the slits?

Have you decided your race colours, yet?

[Hayling mini]

Dont forget to scratch your left testy at 9.30 in the morning when you log on :wink:

[MattG]

Looks tidy Matt 8) Isn´t it a bitch to weld upwards when filling the slits?

Have you decided your race colours, yet?

not that bad if you got a good welder , but there is nothing stopping me from welding from the top :wink:

just did not want to waste to much time .. as i think i will be making new arches in the future anyway.

yes on colours..

ford aqua jade metalic green (body)
bmc marigold orange (roof)

not got a colour code for the orange yet :cry:

these where my dads racing colours

[MattG]

Dont forget to scratch your left testy at 9.30 in the morning when you log on :wink:

offical day off mate :wink:

[MattG]

ok , got to take wife out to lunch in a bit , so mornings work.

i was not going to get Mark's turrets to work , so needed to make some new ones (his are too short for what i needed)

so popped down the local metal suppliers and got to lenths of 4 inch tube (3mm thick ) ..10 quid

http://www.teamorchard.co.uk/wp-content/uploads/2009/03/dscf1704.jpg

i then marked out some circles in some 6mm sheet i had , cut them out

http://www.teamorchard.co.uk/wp-content/uploads/2009/03/dscf1705.jpg

test fit , just needed some shaping


http://www.teamorchard.co.uk/wp-content/uploads/2009/03/dscf1706.jpg

then welded up

http://www.teamorchard.co.uk/wp-content/uploads/2009/03/dscf1709.jpg

started cutting away the arch .. thats a bugger of a job :)

http://www.teamorchard.co.uk/wp-content/uploads/2009/03/dscf1710.jpg

[Mark D]

matt have you ever had any terrorist training, this looks like some kind of pipe bomb your making :lol: :lol: :lol:

http://www.teamorchard.co.uk/wp-content/uploads/2009/03/dscf1706.jpg

[tommi_balls]

sssshhhhhh they will all want one

[Allan McD]

I hav never seen a pipe bomb so I didnt know they looked like that.
What has Mark been upto when he knows about things like that :wink:
Allan

[Mark D]

Ive put some along the track side at olivers, triggered by vauxhall and suzuki sound waves :lol: :lol: :lol:

[MattG]

arrrrrrrr , need to pull my finger out , struggerling to find time around family etc ...

got some fibre glass parts arriving tommorow , and have friday off work .. so should get some done , need to get the car onto 4 wheels again soon !

[cooper_mark]

arrrrrrrr , need to pull my finger out , struggerling to find time around family etc ...
i know how u feel mate...i havn't done anything on mine for about 2 weeks
keep ya chin up.. :wink: and just keep ploding on...(thats what i keep telling myself).. :cry:

[Allan McD]

You need to pull my finger out :wink:
I havnt worked on mine since 10 minutes ago :lol:
Why dont you take a sicky and let the family get on with life on there own for a few days :?:
Allan

[MattG]

Joined the two turrets together to help with positioning :
http://www.teamorchard.co.uk/wp-content/uploads/2009/03/dscf1711.jpg

kept offering them up :

http://www.teamorchard.co.uk/wp-content/uploads/2009/03/dscf1712.jpg

untill they got up there :

http://www.teamorchard.co.uk/wp-content/uploads/2009/03/dscf1713.jpg

need to double check at the weekend...i might lower them a bit.

[Mark D]

Why are you using turrets matt, could you just not have used the parcel shelf :lol: :lol: :lol:

[MattG]

Why are you using turrets matt, could you just not have used the parcel shelf :lol: :lol: :lol:

sticks and stones will break my bones but vtecs will never win :lol:

also lots of fibre glass parts turned up today !!

MAtt

[Allan McD]

It looks fast to me :D faster than any Honda :lol:
Allan

[Mark D]

also lots of fibre glass parts turned up today !!

You guys are getting far too serious for me :lol: :lol: :lol:

[mininut]

Why are you using turrets matt, could you just not have used the parcel shelf :lol: :lol: :lol:

He does have a point Matt :wink: :D

M.

[Andy_S]

You guys are getting far too serious for me :lol: :lol: :lol:
........said the guy who is building the spaceframe ........... :wink:

[MattG]

so after thinking for a few minutes .. i decided to chop the front end off .. its a race car and all that , needs to have a fibre glass front end.

fitted steering rack ,and stuck a bit of black paint on bulkhead for now .. one day it will get stripped again and painted ..

http://www.teamorchard.co.uk/wp-content/uploads/2009/03/dscf1722.jpg

built up and painted the front subframe :

http://www.teamorchard.co.uk/wp-content/uploads/2009/03/dscf1720.jpg

the re-fitted to car again

http://www.teamorchard.co.uk/wp-content/uploads/2009/03/dscf1723.jpg

rebuilt hubs with new bearings ,

http://www.teamorchard.co.uk/wp-content/uploads/2009/03/dscf1724.jpg

i would have had the car on 4 wheels , but i ordered the wrong swival joints for the hubs :oops:

did some more on the rear beam , think i know there the 5th link is going to go now.

painted lots of little things black ...

thanks to wife for lettting my play all day :D

[MattG]

http://www.teamorchard.co.uk/wp-content/uploads/2009/03/dscf1725.jpg

correct swivals turned up yesterday and now fitted ,

missing some wheel studs now :evil: not sure if metro studs are different or not ? but plan on going to 12mm studs at some point anyway...

[mini1]

Those drive flanges look a bit on the thin side....Im sure mine are thicker

Are they mini or metro one?

[MattG]

they are metro one , some i have picked up , looks like someone has machined the lug off , not sure if they have machined acrross the whole flange ?? :shock:

[mininut]

The metro turbo ones are quite thin, i just put some on mine for the fiesta caliper conversion.

M.

[Andy_S]

I've been running the skinny Metro flanges for 2000(ish)miles & they haven't exploded yet :D

Plus the Metty one's are really good if you want to fit beefier studs cos they are bigger diameter than Mini ones & you can oversize the holes.

............. maybe something to think about with the 300hp turbo beast up front. :twisted:

[MattG]

allready have larger studs and nuts :shock: on order.

Matt

[MattG]

welded up and zinked the inner wing where the front end was cut off :

http://www.teamorchard.co.uk/wp-content/uploads/2009/03/dscf1733.jpg

now i have been putting the rust off for now , but started on it ... it needs to be done , two new sills either side , this is the passenger side , drivers side door hinge panel is worse

http://www.teamorchard.co.uk/wp-content/uploads/2009/03/dscf1734.jpg

old sill coming off slowly :
http://www.teamorchard.co.uk/wp-content/uploads/2009/03/dscf1735.jpg

i have some over sills that my dad had , but have cut them in half to form normal size sills.

[mininut]

can you just drill the holes out?? i thought they had to be splined! surely the flanges cant be soft enough for the studs to cut in when pressed?

M.

[MattG]

can you just drill the holes out?? i thought they had to be splined! surely the flanges cant be soft enough for the studs to cut in when pressed?

M.

hmmm , allways been told you can just drill them out , and press them in ... but i never done it before lol

[Spiyda]

can you just drill the holes out?? i thought they had to be splined! surely the flanges cant be soft enough for the studs to cut in when pressed?

M.

hmmm , allways been told you can just drill them out , and press them in ... but i never done it before lol

The studs are definitely harder than the flanges, so drill them out undersize, and whack them in !"

either with a press or a BIG hammer !

[tommi_balls]

yer they have just been pulled in as soon as i did the nuts up in the past.

[juggernaut]

[quote="Andy_S"]I've been running the skinny Metro flanges for 2000(ish)miles & they haven't exploded yet :D

Plus the Metty one's are really good if you want to fit beefier studs cos they are bigger diameter than Mini ones & you can oversize the holes.

............. maybe something to think about with the 300hp turbo beast up front. :twisted:[/quote

Whats the difference in diameter size then?, and is it just the Metro turbo or standard Metros too? Metro turbo ones a bit more offset to them too, that right? :?

[MattG]

the studs on the on a mini flange are quite close to the edge , if you open the holes its VERY close to coming out. if you get me.

i think all metro flanges are like this

Matt

[MattG]

got out again , ground more of the sill off .. nearly gone .. had to stop making noise as kid went to bed :(

so got on with some welding , tacked the 5th link support in :

http://www.teamorchard.co.uk/wp-content/uploads/2009/03/dscf1745.jpg

and removed the top dash rail (guess i should remove the lower one as well .. if not cut the whole dash rail out ??

and laid my dash in just to get a feel :

http://www.teamorchard.co.uk/wp-content/uploads/2009/03/dscf1746.jpg

lots of welding to do , so did some :)

[MattG]

lots of grinding yesterday ..even bought some new goggles so i could see. ... all finished for the night came in side , just before going to bed i blew my nose ..

then a grinding (i think) went into my eye :shock: , cant get it out .. went under the top eye lid

off to the hospital at 9 :shock:

[Andy_S]

oops :(

[MattG]

oops :(

yep , hope i am not scared to go back into the garage again :shock: hope i am allowed to :shock:

[MattG]

can't knock the NHS all the time , i am back , and part of the sill was removed from my eye ...

little sore .. but should be in garage again soon :)

[tommi_balls]

ah nice guess you didnt see that one comming lol. stings a bit, always best to get it taken out asap as you eye grows 4 layers of cells over it each day :shock:

i been to the eye hospital so many times the doctor threatened to take my eye out with a spoon to save herself the trouble next time :lol:

still even with one eye the car seems to be taking shape nicely

[MattG]

popped out at lunch for a bit more grinding .. eye seems ok :) most of old sill gone now , couple of repairs to do to floor , and sill can go on.

then onto other side.

12mm studs and nuts should be here by monday ...lets say next week it will be on 4 wheels :lol:

[MattG]

repaired the floor under the seat box section that allways goes ( i am not proud of the welding here before you say anything aron :oops: ) :

http://www.teamorchard.co.uk/wp-content/uploads/2009/03/dscf1772.jpg

had to repair the front foot weel corner , also welded in some 3mm plate ready for the rollcage to sit on :

http://www.teamorchard.co.uk/wp-content/uploads/2009/03/dscf1773.jpg

Then it was time to spot weld the new sill back on :

http://www.teamorchard.co.uk/wp-content/uploads/2009/03/dscf1775.jpg

then some stone chip sprayed on just to protect it for now , one day it might all get sprayed :)

http://www.teamorchard.co.uk/wp-content/uploads/2009/03/dscf1777.jpg

http://www.teamorchard.co.uk/wp-content/uploads/2009/03/dscf1776.jpg

will fit a-panel after i have done the other side , then i can fit the front end as well.

so clean up time , and then start on the other side .. which is worse :evil:

[Allan McD]

It wont look to bad with just one eye :wink:
Allan

[charlie_t]

always best to get it taken out asap as you eye grows 4 layers of cells over it each day :shock:
oh now he tells me! :lol: i got a grinding in my eye and thought it wous come out over night, my eye swelled up next day and had to have an operation on my eye :oops:

[Allan McD]

I have had loads in my eyes they have always came out in my sleep.
You wont scare me you boys.
Ps I do wear gogles now but still get things in somtimes.
Allan

[MattG]

my 12mm studs arrived , with new 'tuning' style nuts to match the wheels.

http://www.teamorchard.co.uk/wp-content/uploads/2009/03/dscf1780.jpg

old mini stud on left , new ford 12mm stud on right :

http://www.teamorchard.co.uk/wp-content/uploads/2009/03/dscf1781.jpg

time to start attacking the rust on the drivers side , first over sill came off ,(nearly fell off)

http://www.teamorchard.co.uk/wp-content/uploads/2009/03/dscf1783.jpg

old patch repairs had to be cut off :

http://www.teamorchard.co.uk/wp-content/uploads/2009/03/dscf1784.jpg

top scuttle area will need some work :

http://www.teamorchard.co.uk/wp-content/uploads/2009/03/dscf1785.jpg

first new piece of metal going on , both panels for the door hinge are rotton , so had to weld new on :

http://www.teamorchard.co.uk/wp-content/uploads/2009/03/dscf1786.jpg

big hole in floor , could really do with a floor panel to cut a corner off .. but will have to just fabricate a new floor :

http://www.teamorchard.co.uk/wp-content/uploads/2009/03/dscf1787.jpg

sorry for all the rust pics ...

[Spiyda]

Re the studs... I guess they are OK for Ally wheels... do they run out of thread on the thinner hub flanges for steel wheels ?

[MattG]

Re the studs... I guess they are OK for Ally wheels... do they run out of thread on the thinner hub flanges for steel wheels ?

i guess , but there are many different studs you can buy with different lengths of thread etc .. these where just cheap 8)

[juggernaut]

Is that the Metro drive flange in the pic Matt? If it is I see what you mean about the extra metal around the holes, will have to get some Metro flanges methinks. What you doing about the rear flanges/ wheels?, do you reckon there is enough metal on the Mini rear flanges for your new studs?

[MattG]

Is that the Metro drive flange in the pic Matt? If it is I see what you mean about the extra metal around the holes, will have to get some Metro flanges methinks. What you doing about the rear flanges/ wheels?, do you reckon there is enough metal on the Mini rear flanges for your new studs?

yes it is a metro drive flange.

will leave rears for now , as i am just fitting them to the front to cope with the extra power .. will do rears one day just so i have common nuts :shock: :?

Matt

[tommi_balls]

always best to get it taken out asap as you eye grows 4 layers of cells over it each day :shock:
oh now he tells me! :lol: i got a grinding in my eye and thought it wous come out over night, my eye swelled up next day and had to have an operation on my eye :oops:

shall we start a new mini medical advice thread :D

[MattG]

dropped the metro flanges off today at a local machine shop , they are going to drill out old metro holes to 12.5mm and press the studs in for me.

I am sure i will need to cut the studs down as they are very long .. but will do that once i have them back to try on the alloys.

new gaskets and head bolts from GM arrived :

http://www.teamorchard.co.uk/wp-content/uploads/2009/04/dscf1792.jpg

also picked up a coil pack of a 1.6 vauxhall as the std 8v coil and dizzy start to muck around under high boost .. so might as well sort it now.

http://www.teamorchard.co.uk/wp-content/uploads/2009/04/dscf1793.jpg

Megasquirt should be with me Saturday so will have to start building that up (will fit it inside old GM ecu case :)

had to get engine over to my nieghbour as he's got a pressure washer , so bolted engine onto childs go cart to move :

http://www.teamorchard.co.uk/wp-content/uploads/2009/04/dscf1791.jpg

somthing about that picture makes me think the engine should not go in a mini :twisted:

crack on with more rust tommorow , clean engine and paint it .

[Owen]

That would make one fast kart. Mind your kids don't get hold of that motor! :lol:


Looking good Matt, how come you didn't go for the head stud kit?

[MattG]

Looking good Matt, how come you didn't go for the head stud kit?

well they still dont have the ARP nuts yet , and thought i should just get this engine in quick ...

i will still get a set , then i can build up a new bottom end during the year as i am pretty sure this 150k bottom end wont last long.

got my eyes on a VXR bottom end :wink:

[Owen]

Ah fair do's.


got my eyes on a VXR bottom end :wink:


Do they do a turbo version?


Also out of curiosity, on your current head, is it cracked between the valve seats? It's supposedly quite common on the 8v's.

[MattG]

Ah fair do's.


got my eyes on a VXR bottom end :wink:


Do they do a turbo version?


Also out of curiosity, on your current head, is it cracked between the valve seats? It's supposedly quite common on the 8v's.

maybe its just me , i thought VXR's where turbo's ...

not sure on head , will see next week when it comes off ... its going back on regardless :lol: :lol:

[Spiyda]

Are you building the Megasquirt from components?

Its no mean task to work out the configuration you need...

However long you think it will take, double it !

much easier if someone has built it with exactly the same peripherals..

Chris (-=Spiyda=-)

[MattG]

Are you building the Megasquirt from components?

Its no mean task to work out the configuration you need...

However long you think it will take, double it !

much easier if someone has built it with exactly the same peripherals..

Chris (-=Spiyda=-)

its not my first ... 8) bought a jstim as well so should be a good learning curve ....

[Allan McD]

You wont need to worry about the head etc for a long time if you are going to build a Megasquirt :shock:
Megasquirt is brilliant but not easy to understand for normal people.
Allan
Ps I see you have built them before so it will be easy peasy

[Owen]

not sure on head , will see next week when it comes off ... its going back on regardless :lol: :lol:


Apparently it's fine anywho, if they didn't have inserts as standard it would be a problem (or so I'm told as I thought my head was goosed) :lol: .


Not sure about the 2ltr VXR's, hopefully they are turbo motors!

[MattG]

You wont need to worry about the head etc for a long time if you are going to build a Megasquirt :shock:
Megasquirt is brilliant but not easy to understand for normal people.
Allan
Ps I see you have built them before so it will be easy peasy

target to get the engine running by the end of this month (30th on my birthday would be a good present)

[evolotion]

corsa vxr 1.6 turbo, astra vxr 2.0 turbo, vectra vxr 2.6 v6 turbo :)

hint hint

[tommi_balls]

well good luck with that. i want a turbo :(

gotta restrain myself, your looks like its going to be a tool tho matt.

i save it for the next one. im thinking 3s-gte rwd then i might keep up with you lol

[tommi_balls]

corsa vxr 1.6 turbo, astra vxr 2.0 turbo, vectra vxr 2.6 v6 turbo :)

hint hint

is it a XE based engine???

[MattG]

corsa vxr 1.6 turbo, astra vxr 2.0 turbo, vectra vxr 2.6 v6 turbo :)

hint hint

is it a XE based engine???

yes .. basically ... same block ... for our needs anyway...

[tommi_balls]

so basically 2.0 VXR = C20LET. humm now why did u have to tell me that. this could get expensive now lol

[MattG]

so basically 2.0 VXR = C20LET. humm now why did u have to tell me that. this could get expensive now lol

think its based on a Z20LET , which is found in the 220 turbo's etc.. Z is the later turbos ...

[Owen]

so basically 2.0 VXR = (low mileage) C20LET. humm now why did u have to tell me that. this could get expensive now lol

:wink:

[Spiyda]

You wont need to worry about the head etc for a long time if you are going to build a Megasquirt :shock:
Megasquirt is brilliant but not easy to understand for normal people.
Allan
Ps I see you have built them before so it will be easy peasy

I knew we weren't normal :D

I don't think it would ever be easy peasy, unless the build is identical each time... too many variables

The hardest bit when I built Pete's was sorting out the EDIS stuff .. but well worth it, its a cracking ignition system.. but there again I was brought up on magnetos :)

I believe it's easier with the later version.

It would be nice to have a decent colour dashboard display with megatune or similar running on it that would auto boot up when the ignition is turned on..... has anyone managed that with a PDA or something ?

[MattG]

I believe it's easier with the later version.

It would be nice to have a decent colour dashboard display with megatune or similar running on it that would auto boot up when the ignition is turned on..... has anyone managed that with a PDA or something ?

i am using the std vauxhall coil pack and crank sensor so should be simple :)

was surfing around yesterday on how to build a carputer ... then that could run megatune...

i had a PDA connected on my old one .. but it was a old PDA so just showed VE table .. no dials.

Matt

[mini1]

That pallet looked a bit OTT for posting that coil pack on!! :lol:

[MattG]

after jetwashing the engine i painted the block up a bit :

http://www.teamorchard.co.uk/wp-content/uploads/2009/04/dscf1796.jpg

just bolted turbo on to see about oil return :

http://www.teamorchard.co.uk/wp-content/uploads/2009/04/dscf1797.jpg

repaired the door step : (again aron not proud of the welding .. filler will hide it :wink: )

http://www.teamorchard.co.uk/wp-content/uploads/2009/04/dscf1803.jpg

inner wing now welded in :

http://www.teamorchard.co.uk/wp-content/uploads/2009/04/dscf1798.jpg

and just started on repairing the scuttle panel

http://www.teamorchard.co.uk/wp-content/uploads/2009/04/dscf1799.jpg

[MattG]

parts laid out for the JimStim (jim stim is used to test the megasquirt on a bench before it even sees a car )

http://www.teamorchard.co.uk/wp-content/uploads/2009/04/dscf1804.jpg

my 8 year old helping me , (untill her bed time came and i had to carry on by myself :(
http://www.teamorchard.co.uk/wp-content/uploads/2009/04/dscf1805.jpg

3 hours later , a working jimstim :

http://www.teamorchard.co.uk/wp-content/uploads/2009/04/dscf1806.jpg

just need to make the ECU next :shock:

[Allan McD]

I used to have a megastim but lent it out to a fellow 16valver in 2007 but never got it back.
This may remind him you never know.
Allan
Ps that looks more advanced than the one I had.

[Spiyda]

Hmmnn

I wonder who that was ? :oops:

Chris (-=Spiyda=-)

ps it does look more advanced than yours :)

pps you did say keep it until we had finished with it !

[*franky*]

matt how much did that kit cost? looks like you have built one befor. builds lookin very good mate keep it up.

[MattG]

Ps that looks more advanced than the one I had.

yes , this is a "jimstim" (love the names of these things ) designed by a bloke called Jim funny enough :)

its got a processor on it , so it can simulate different crank wheel setups.
also has allot more LED's for checking all the outputs.

Matt

[MattG]

matt how much did that kit cost? looks like you have built one before. builds lookin very good mate keep it up.

yes have built one before , this kit came from glensgarage from the US , came in a week or so , every bag labeled and was very simple to follow the build manual (even my 8 year old was doing it)

for ECU and stim it was around 200 uk pounds .. but can be got cheaper if sourced from UK , or even sourced your own components

Matt

[MattG]

ordered 3 inch exhaust parts this morning , should have all the parts to make a system now , (will find out next week i hope )

trying to think of somthing different with the tail pipes .. got an idea but will see how it goes next week... remember i have to go over the rear beam now !

Matt

[Andy_S]

ordered 3 inch exhaust parts this morning , should have all the parts to make a system now , (will find out next week i hope )

trying to think of somthing different with the tail pipes .. got an idea but will see how it goes next week... remember i have to go over the rear beam now !

Matt

You might be able to go under your axle depending on the ride height / suspension drop of your racer ......... :idea:

Tape measure engineering suggests that a straight through system will sneak under my axle at full drop because the top of the exhaust tunnel remains lower than the axle. Will find out for sure this evening because it's time to play with the loud pipe.

[MattG]

we shall see ...

i seem to be drifting a little away from it being a full blown sprint car ... i will still be doing the 16v sprint champ , but i also want to add a few items to the car which wont really make the car be a full race car :)

but being a road car as well has allready limited it to not being a full race car.

Matt

[Andy_S]

Much more fun when they're road legal cos you get the best of both worlds :D.

(I'm trying to convince Mini-Sprite to make Stella road legal again!)

[PaulW]

Much more fun when they're road legal cos you get the best of both worlds :D.

(I'm trying to convince Mini-Sprite to make Stella road legal again!)

Keep going dude but not anytime soon :D

Paul

[MattG]

12mm studs fitted to metro flanges :

http://www.teamorchard.co.uk/wp-content/uploads/2009/04/dscf1807.jpg

just need trimming down :

http://www.teamorchard.co.uk/wp-content/uploads/2009/04/dscf1809.jpg

[tommi_balls]

you have got the wheels im going to order. 8) whats the offset like????

have you any pictures of them on the car??

[Spiyda]

So where did the 12mm studs and nuts come from ?

[MattG]

12mm studs came from a ford , ebay .

drivers floor patched up :

http://www.teamorchard.co.uk/wp-content/uploads/2009/04/dscf1850.jpg

looks worse that it is , as one of those patches is the 3mm cage floor plate

working back down the car now , patching the rear floor , then sill can go on.

got my two front hubs finally built , so got the passenger front wheel on (using 12mm studs ) all seems ok. had to fit a 5mm spacer , because the thread on the studs is not long enough (will change studs again soon )

http://www.teamorchard.co.uk/wp-content/uploads/2009/04/dscf1849.jpg

all my exhaust parts have arrived , and a few extra bits :wink:

L2B only 4 weeks away , and more than 4 weeks of work to be done :shock:

[matt]

Loving this build such a fast worker. :mrgreen:

We have a good taste for wheels :lol:

But a shame you choice a Vauxhall engine :P at least your putting a turbo on it.

[MattG]

megasquirt 99% done :

http://www.teamorchard.co.uk/wp-content/uploads/2009/04/dscf1853.jpg

http://www.teamorchard.co.uk/wp-content/uploads/2009/04/dscf1854.jpg

engine re-build next .. i am really not spending enough time on this car :)

[NudgerSS]

A lot more than I am spending on mine!

John

[MattG]

http://www.teamorchard.co.uk/wp-content/uploads/2009/04/dscf1856.jpg

Dis pack adaptor plate made to cover up old dizzy hole.

[MattG]

engine in bits , ready for LET pistons :
http://www.teamorchard.co.uk/wp-content/uploads/2009/04/dscf1857.jpg
http://www.teamorchard.co.uk/wp-content/uploads/2009/04/dscf1858.jpg

[MattG]

sump modded for turbo oil outlet :

http://www.teamorchard.co.uk/wp-content/uploads/2009/04/dscf1859.jpg

3 LET pistons fitted :

http://www.teamorchard.co.uk/wp-content/uploads/2009/04/dscf1860.jpg

bought another 3 2nd hand only to find out that they are over size :twisted: so now need anout LET piston before engine can go back together :evil:

clutch slave fitted

http://www.teamorchard.co.uk/wp-content/uploads/2009/04/dscf1861.jpg

XE injectors fitted :

http://www.teamorchard.co.uk/wp-content/uploads/2009/04/dscf1862.jpg

head stripped , as i have a few snapped studs that will need sorting

http://www.teamorchard.co.uk/wp-content/uploads/2009/04/dscf1863.jpg

my kid painted things for me :
http://www.teamorchard.co.uk/wp-content/uploads/2009/04/dscf1864.jpg

did some more rust repairs untill i run out of wire , so finished cutting the dash rail out...

[Hayling mini]

You cant beat child labour, its free :D

Looking good Matt, cant wait to see it on the stand in Brighton :D

[MattG]

the holy grail, a LET piston , picked up on my way home :

http://www.teamorchard.co.uk/wp-content/uploads/2009/04/dscf1866.jpg

fitted to a spare let rod i had :

http://www.teamorchard.co.uk/wp-content/uploads/2009/04/dscf1867.jpg

fitted to block , , new sump gasket and modded sump on :

http://www.teamorchard.co.uk/wp-content/uploads/2009/04/dscf1868.jpg

new clutch , just a std cheap item for now ...

http://www.teamorchard.co.uk/wp-content/uploads/2009/04/dscf1869.jpg

[Allan McD]

new clutch , just a std cheap item for now ...

Will a cheap clutch handle 450bhp :shock:
Allan

[MattG]

new clutch , just a std cheap item for now ...

Will a cheap clutch handle 450bhp :shock:
Allan

dont think so .. but gearbox will have to come out again when i can afford a LSD anyway..

i am planning on blowing the engine up this year anyway :wink:

[Allan McD]

450bhp and no LSD thats like one wheel drive you will need about 15" wide front tyres :lol:
Allan

[MattG]

450bhp and no LSD thats like one wheel drive you will need about 15" wide front tyres :lol:
Allan

where did you get this 450 bhp from :lol: :lol: :lol:

[Allan McD]

Its your power not mine :lol:
Allan

[MattG]

Its your power not mine :lol:
Allan

do you think 450 is enough to beat the vtec boys ? :) :wink:

[Allan McD]

Its your power not mine :lol:
Allan

do you think 450 is enough to beat the vtec boys ? :) :wink:
I think I will be able to do it with a mere 200bhp 8) I did last year :lol:
Yours will be fast enough.
Allan

[MattG]

lets just hope i can make an event this year :shock:

hope to make one at least ... cant wait ..

[MattG]

got up early before going to work , and aligned clutch and fitted gearbox :

http://www.teamorchard.co.uk/wp-content/uploads/2009/04/dscf1871.jpg

had to remove sump again as i did somthing wrong :oops: but all back together.

fitted starter , just need to fit pipe work , trim a few bits off the gearbox and fit the engine the mounts.

[mininut]

Just for reference Matt, to achieve 450 horse in the 2.0 8v, you'll need to run near 38lb of boost :shock:

Have to say you're well motivated to get up early and get the box on!

Edit... On your sump, the return for the oil from the turbo is pointing up, this will cause oil to sit in the dip and may cause a blockage at some point with debris and muck in the oil.

M.

[MattG]

Have to say you're well motivated to get up early and get the box on!

M.

cheers .. not sure how many days i can do that for LOL .

still loads to do , cant even roll the thing yet .. and i have a L2B club stand ticket :shock:

[Mark D]

do you not also have an entry in for olivers mount in May (weekend after next)

It's pleanty of time allan had his car built in a week

[MattG]

not making olivers mount .... :oops: aiming for elvington.

put some etch primer on the bulkhead after a bit of a grind down , will have to get painted another day ....

http://www.teamorchard.co.uk/wp-content/uploads/2009/04/dscf1872.jpg

rear mount on , and dummy drive shaft , threads needed cutting again for that as the holes on the 8v block are used for it normal (8v does not normally have a dummy drive shaft)

http://www.teamorchard.co.uk/wp-content/uploads/2009/04/dscf1873.jpg

and front mounts on
http://www.teamorchard.co.uk/wp-content/uploads/2009/04/dscf1874.jpg

ground some of the lugs off the gearbox that get close to subframe.

engine nearly ready to go back in (for the last time until i blow it up )

[tinxy]

hmmm i think it depends on the engine weather the 8v has the dummy shaft mine deffinatly did :?

have you recived that ecu i sent i only sent it second class non recoreded



looking ace so far tho i want to turbo my 8ver now have you seen the power they get :D over 200bhp on mega squirt on a standard block :twisted:

[MattG]

have you recived that ecu i sent i only sent it second class non recoreded

nope did not get it ? :cry:

guys on vaux extreme are seeing 300 with a few mods :)

[MattG]

ok , could not got to sleep without putting the engine in :

http://www.teamorchard.co.uk/wp-content/uploads/2009/04/dscf1876.jpg

got to be adjusted yet , but its in ... my birthday on the 30th , wonder if i can have first engine start on that day :P
bed now ...

[caveman]

coming on nicley matt ,9days to go thats some going that would be a lovly birthday present



p.s what rubber mounts did u use

[tinxy]

ahh yeah ive been on vaux extreme a few times but it gives me too many ideas lol


u want me to send another one ive got about 8 ecus now lol

[MattG]

ahh yeah ive been on vaux extreme a few times but it gives me too many ideas lol


u want me to send another one ive got about 8 ecus now lol

nah , you are fine mate , dont worry for now.

[MattG]

ok , drivers floor repaired , and new drivers sill on , just need to put some stone chip on it ..

might be on 4 wheels tommorow !!!

Matt

[MattG]

drivers side hub fitted :

http://www.teamorchard.co.uk/wp-content/uploads/2009/04/dscf1878.jpg

it could go down onto 4 wheels now if i wanted ! but in two minds to keep it up as i have to do the exhuast system early next week ...

got to have a big clean up next i think

[tommi_balls]

is that tiebar bent???

[MattG]

is that tiebar bent???

yes , its supose to be , as the front tie bar points are further out than a std mini , so they are bent to still give clearance to brake calipers etc.

Matt

[MattG]

bit of a clean up ,trip to the tip with a load of rusty off cuts...

bolted all 4 wheels on , and lowered car down , all carrying its own weight :

http://www.teamorchard.co.uk/wp-content/uploads/2009/04/dscf1879.jpg

started working on front end fitment, :

http://www.teamorchard.co.uk/wp-content/uploads/2009/04/dscf1880.jpg

and just playing with the exhaust system :

http://www.teamorchard.co.uk/wp-content/uploads/2009/04/dscf1882.jpg

[MattG]

got the fixing tabs tack welded to a-panels , just going for the simple bolt aproach to hold the front end on :

http://www.teamorchard.co.uk/wp-content/uploads/2009/04/dscf1884.jpg

same at the front , will make somthing that comes off the subframe, :

http://www.teamorchard.co.uk/wp-content/uploads/2009/04/dscf1883.jpg

will replace bolts with dome headed bolts at some point ...

[Allan McD]

You need a few of these :wink:
http://www.leofixings.com/images/large_images/ROOFING-BOLT-AND-NUT.jpg
Its all the rage in the racing scene :lol:
Allan

[tommi_balls]

matt next time your with the car could you either take a picture of the wheel offset or measure it mate

pleaseee :)

[MattG]

sorry still not messured the wheels , will do thursday.

got the head back on , not tight yet , and tested turbo position now in a extended round nose :

http://www.teamorchard.co.uk/wp-content/uploads/2009/04/dscf1961.jpg

http://www.teamorchard.co.uk/wp-content/uploads/2009/04/dscf1962.jpg

now for now i am thinking of mounting the IC to the front end , where the grill would be ... just for quickness , but there is room for it above the plugs behind the bonnet ... but not sure on flow ...

so for now , slap it on the front , no hidding it ..

[MattG]

fibreglass roof arrived :

http://www.teamorchard.co.uk/wp-content/uploads/2009/04/dscf1964.jpg

just rested on for now , will send it to paint shop to get painted first :) then stick it on ! lol

finished front end mounts and painted black :

http://www.teamorchard.co.uk/wp-content/uploads/2009/04/dscf1965.jpg

started welding the cage in , taking ages :

http://www.teamorchard.co.uk/wp-content/uploads/2009/04/dscf1966.jpg

and also started to weld it to the shell before i cut the roof off ! LOL

http://www.teamorchard.co.uk/wp-content/uploads/2009/04/dscf1967.jpg

also got my cam cover back from the paint shop , this will be the same colour as the roof :

http://www.teamorchard.co.uk/wp-content/uploads/2009/04/dscf1968.jpg

as you can tell , i did not start it today :( , need to source a turbo oil feed pipe first ... hope to get the cage finished off and a exhaust made over the weekend ... we shall see...

[tinxy]

looking ace man did you get those gussets off ebay i bidded on some ages ago i want them now baldy now they look ace

[NudgerSS]

looking ace man did you get those gussets off ebay i bidded on some ages ago i want them now baldy now they look ace

Who you calling baldy?? :?

[Miniwidow]

LOL I was going to say that :lol: :lol: :lol:

[MattG]

looking ace man did you get those gussets off ebay i bidded on some ages ago i want them now baldy now they look ace

http://www.16vminiclub.com/forums/viewtopic.php?t=16409

[BassAddict]

Not been on much lately so this is the first time I've seen the diary Matt - looks like its coming on nicely !!! :) Shame about the ebay manifold being bust :(
Happy Birthday ! :)

[Hayling mini]

Looking the nuts Matt, love those gussets, feel sure I have seen them somewhere before :D

Jerry

[NudgerSS]

I don't suppose there is a flange on the gusset is there or is it just my filthy mind?

Hee hee - sorry couldn't resist it any longer :wink:

[MattG]

got bored of welding .. so did some bolting up :)

adjusted engine position on mounts and tightened them up , fitted 4 th mount.

head down tight , and put my nice painted cam cover on ! , bolted turbo manifold up and turbo on :

http://www.teamorchard.co.uk/wp-content/uploads/2009/05/dscf1969.jpg

had to do rotate crank case sensor as it was stopping the compressor from turning around , all sorted now.

http://www.teamorchard.co.uk/wp-content/uploads/2009/05/dscf1972.jpg

made some mounts up for the inter cooler , worked out how to mount it to the subframe so will still allow the front end to be removed :

http://www.teamorchard.co.uk/wp-content/uploads/2009/05/dscf1973.jpg

also fitted my cheapo air filter to see how it looked.

http://www.teamorchard.co.uk/wp-content/uploads/2009/05/dscf1974.jpg

and a few shots of the front end fitted :

http://www.teamorchard.co.uk/wp-content/uploads/2009/05/dscf1976.jpg

http://www.teamorchard.co.uk/wp-content/uploads/2009/05/dscf1975.jpg

really like how its looking now ... doing the fun bits ! , cant wait to make the exhuast system .... :P

[Smurfy]

Thats looking great, I'm looking forward to seeing this in action.

[chris alderman]

that is sweet, love the cam cover and that intercooler is huge, i think it will do the job. you are putting this car together at some speed.

[S_Davis]

Coming together very quickly indeed,

Sorry if this has already been mentioned but where is the radiator going in order to get good airflow?

Ta

[MattG]

you can see the rad in this pic , its a honda rad , but i have turned it on its side , will get the fittings moved soon and block off the cap.

in between family things today i did :

started on the boost pipes , think i have the rough layout , just need to order some silicon bends to finish it off , then i can fit for final time,

http://www.teamorchard.co.uk/wp-content/uploads/2009/05/dscf1977.jpg

pic of the inlet side , with T peice for dump valve.

http://www.teamorchard.co.uk/wp-content/uploads/2009/05/dscf1978.jpg

if anyone can see somthing i have done wrong , please say.

did some more welding on cage , and started to mount the waste gate actuator. and i still need to squeeze in a alternator ! LOL

[evolotion]

your going to be grinning like a cheshire cat when that comes on boost :D :D

[S_Davis]

The Alu rad looks nice and big

Will you make additional holes in the bodywork / front end or rely on the secondary air through the IC?

[Rob H]

Looks like you're making good progress, it's definitely coming on quickly.

started welding the cage in , taking ages :

Tell me about it, I think I've sunk about 50 hours into my cage & there's still more to go, the worst bit is contorting you self into silly places to weld round the back of the tubes.

[MattG]

finsihed off and painted the waste gate actuator bracket , think i can just get the vacum pipes onto it ...
http://www.teamorchard.co.uk/wp-content/uploads/2009/05/dscf2028.jpg

then dug out all my exhaust bits :
http://www.teamorchard.co.uk/wp-content/uploads/2009/05/dscf2027.jpg

after a few hours i got the down pipe complete (just need to fit lamba boss's ) i think it looks ok ...love the 3" size LOL
http://www.teamorchard.co.uk/wp-content/uploads/2009/05/dscf2029.jpg

[*franky*]

did the fosters help matt :twisted:

[MattG]

aye , fosters helped :wink:

[MattG]

raditator mounted :

http://www.teamorchard.co.uk/wp-content/uploads/2009/05/dscf20321.jpg

i will use the hole where the old filler neck was to mount a fan switch.
http://www.teamorchard.co.uk/wp-content/uploads/2009/05/dscf20341.jpg

top hose outlet moved around to the side , just needs welding up now , will use the fitting above it as a feed back to the header tank i think.

http://www.teamorchard.co.uk/wp-content/uploads/2009/05/dscf20351.jpg

[Harry red min]

It was great to see the beast in the flesh on sunday its coming on a treat

[bousfield19]

just a quick question matt where will ur alternator be going it looks like you have forgotten about this?

[MattG]

just a quick question matt where will ur alternator be going it looks like you have forgotten about this?

the plan is under the throttle body :shock:

[MattG]

my good friend Jim welded up my honda rad , and turned it into a vauxhall rad :)

moved fitting around to the side :
http://www.teamorchard.co.uk/wp-content/uploads/2009/05/dscf20391.jpg

welded in fitting for the vauxhall fan switch :

http://www.teamorchard.co.uk/wp-content/uploads/2009/05/dscf20401.jpg

also i bought his old TIG plant , and did my first ever TIG weld , welded in the O2 bung into the down pipe :

http://www.teamorchard.co.uk/wp-content/uploads/2009/05/dscf20371.jpg

not bad for my first attempt , need to feed in a bit quicker in parts ... but should not come off.

[Marcus Nordblom]

Speed and quality!

[MattG]

ok , time to finish off the boost pipes , i made the tool that geehawk posted a like to :

http://www.teamorchard.co.uk/wp-content/uploads/2009/05/dscf20411.jpg

this is what it did to the end of the pipe :

ok could be better and cleaner .. but will do the job ... and is all hidden under silicon !

http://www.teamorchard.co.uk/wp-content/uploads/2009/05/dscf20431.jpg

overall shot ...
http://www.teamorchard.co.uk/wp-content/uploads/2009/05/dscf20441.jpg

[2lrMiniVan]

looking good
was wondering what size nuts head u are using with the new wheel studs
as i can only find 19mm head ones and i will not be able to fit a socket that big on my revos
chees
Andy

[Geehawk]

ok , time to finish off the boost pipes , i made the tool that geehawk posted a like to :

http://www.teamorchard.co.uk/wp-content/uploads/2009/05/dscf20411.jpg

this is what it did to the end of the pipe :

ok could be better and cleaner .. but will do the job ... and is all hidden under silicon !



Um. You made a tool similar to the one I posted a link to, but welded it back to front (saddle and washer on the wrong bits of the clamp) might make a difference to it's effectiveness :wink:
http://i532.photobucket.com/albums/ee330/Dayosgarage/Finishedproduct2.jpg
Also looks like you were trying to form the bead too near the end of the pipe.
http://i532.photobucket.com/albums/ee330/Dayosgarage/Sweetbead.jpg

[MattG]

looking good
was wondering what size nuts head u are using with the new wheel studs
as i can only find 19mm head ones and i will not be able to fit a socket that big on my revos
chees
Andy

on these wheels they are those "Tuning" nuts , so you have a allan "type" key that goes inside them , so dont really have a nut

Matt

[2lrMiniVan]

ah ok that might work

[mininut]

Um. You made a tool similar to the one I posted a link to, but welded it back to front

:lol: :lol: Only Matt could do that :lol: :lol:

M.

[Body Stylist]

good to see my cardboard boxes being put to use :lol:

[MattG]

dont think it really mattered ... seemed to do the job LOL

Matt

[MattG]

boost piping all done and clamped up :

http://www.teamorchard.co.uk/wp-content/uploads/2009/05/dscf20451.jpg

http://www.teamorchard.co.uk/wp-content/uploads/2009/05/dscf20461.jpg

there are a few bits i am not quite happy with , but will see how they go , and improve over time , want to replace all silicon with orange one day anyway LOL

front end on , just goes over it :) ,i might tart it up a bit with mesh or somthing but dont car for now :)

http://www.teamorchard.co.uk/wp-content/uploads/2009/05/dscf20471.jpg

also re-fitted down pipe , and made bracket to mount to rear of block, as its quite heavy :)

Just waiting on radiator pipes to turn up :cry:

[mininut]

where are you going to put the alternator mate? :shock:

M.

[KMP]

wow just come across this build and this is fantastic! excellent effort son top marks 8)

[MattG]

where are you going to put the alternator mate? :shock:

M.

should fit under the throttle body behind the engine .. well it better as thats the only place for it ! LOL