tink - small bore 16v

[alexcrosse]

My mini is called tink...

tink version 1: 1275 stage 1
http://photos-e.ak.fbcdn.net/photos-ak-sf2p/v158/122/70/509954329/n509954329_169756_9636.jpg
got bored of that...

tink version 2: 1430
http://photos-b.ak.fbcdn.net/photos-ak-sf2p/v173/122/70/509954329/n509954329_270161_1387.jpg
http://photos-d.ak.fbcdn.net/photos-ak-sf2p/v158/122/70/509954329/n509954329_169771_3906.jpg
with the realization that A series can only be taken so far before costs get in 5 figures... i moved on

tink version 3: R1
http://photos-c.ak.fbcdn.net/photos-ak-snc1/v312/122/70/509954329/n509954329_680770_4480.jpg
i use my mini to commute as its my only car... and this proved to not be a daily driver, 105dB static had something to do with it, so sold the R1 setup and decided a vauxhall lump was the way to go

tink version 4: C16SE
http://photos-e.ak.fbcdn.net/photos-ak-snc1/v2074/122/70/509954329/n509954329_1225068_9849.jpg
http://photos-b.ak.fbcdn.net/hphotos-ak-snc1/hs007.snc1/2624_58322419329_509954329_1454793_2711032_n.jpg
this is what i am currently using, but with a little project going on in the garage... the new lump!

tink version 5: X16XE (Current project)
http://photos-c.ak.fbcdn.net/hphotos-ak-snc1/hs025.snc1/3123_72932854329_509954329_1581050_4426782_n.jpg
the lump i bought

http://photos-b.ak.fbcdn.net/hphotos-ak-snc1/hs113.snc1/4681_89521739329_509954329_1807697_6815374_n.jpg
everything stripped

http://photos-c.ak.fbcdn.net/hphotos-ak-snc1/hs113.snc1/4681_89521744329_509954329_1807698_7896158_n.jpg
block ready for machining

http://photos-e.ak.fbcdn.net/hphotos-ak-snc1/hs113.snc1/4681_89521759329_509954329_1807700_3011534_n.jpg
started cleaning the head

http://photos-h.ak.fbcdn.net/hphotos-ak-snc1/hs093.snc1/4681_89521779329_509954329_1807703_5005235_n.jpg
skimmed & honed block... and painted ofcourse! lol

http://photos-c.ak.fbcdn.net/hphotos-ak-snc1/hs113.snc1/4681_89521794329_509954329_1807706_7994721_n.jpg
dry assembled with plastigauge inside

http://photos-d.ak.fbcdn.net/hphotos-ak-snc1/hs093.snc1/4681_89521799329_509954329_1807707_1372635_n.jpg
measuring the clearances, all ok with new bearings :)

http://photos-e.ak.fbcdn.net/hphotos-ak-snc1/hs093.snc1/4681_89521804329_509954329_1807708_6427119_n.jpg
all torqued up with lots of oil and high tensile bolts! £3 each, cheers SMMC!

http://photos-g.ak.fbcdn.net/hphotos-ak-snc1/hs113.snc1/4681_89521824329_509954329_1807710_7676387_n.jpg
pistons all cleaned up, new rings, ready to go in

http://photos-a.ak.fbcdn.net/hphotos-ak-snc1/hs113.snc1/4681_89521834329_509954329_1807712_7656297_n.jpg
finished rebuilding the head, new exhaust valves, stem seals, skimmed

http://photos-c.ak.fbcdn.net/hphotos-ak-snc1/hs093.snc1/4681_89521844329_509954329_1807714_833653_n.jpg
http://photos-e.ak.fbcdn.net/hphotos-ak-snc1/hs113.snc1/4681_89521859329_509954329_1807716_7987293_n.jpg
yum yum, did some porting aswell you cant see here, to improve inlet port dynamics with my chosen induction...

http://photos-e.ak.fbcdn.net/hphotos-ak-snc1/hs007.snc1/2624_57269754329_509954329_1439516_1479227_n.jpg
45mm jenveys with MBE ecu and innovate wideband

http://photos-h.ak.fbcdn.net/hphotos-ak-snc1/hs097.snc1/4975_89878039329_509954329_1812351_699877_n.jpg
pistons in and big end caps on

http://photos-a.ak.fbcdn.net/hphotos-ak-snc1/hs097.snc1/4975_89878044329_509954329_1812352_1758136_n.jpg
ARP conrod bolts and a shot of the high tensile main bolts too. ARPs done up with their funny, take up slack and removed 3 times, lube lube lube, rubbish, but if it lets it rev to 7750 who cares =p

http://photos-b.ak.fbcdn.net/hphotos-ak-snc1/hs117.snc1/4975_89878054329_509954329_1812353_6590346_n.jpg
Piston shot in, yes, number 1 piston is missing, broken ring, new one on order. These pistons are awful to get it in my opinion. loads of hassle

http://photos-c.ak.fbcdn.net/hphotos-ak-snc1/hs117.snc1/4975_89878064329_509954329_1812354_1731235_n.jpg
not quite TDC, minimal 'squish' when it is at TDC though

http://photos-d.ak.fbcdn.net/hphotos-ak-snc1/hs097.snc1/4975_89878069329_509954329_1812355_3145489_n.jpg
oil pump and seal is mounted and inserted

http://photos-d.ak.fbcdn.net/hphotos-ak-snc1/hs085.snc1/4591_90271794329_509954329_1818123_5930388_n.jpg
bit of graphics i painted on the cam cover, version 5 :)
http://photos-e.ak.fbcdn.net/hphotos-ak-snc1/hs105.snc1/4591_90271804329_509954329_1818124_6029698_n.jpg
painted the cylinder head, all coming together :D
http://photos-f.ak.fbcdn.net/hphotos-ak-snc1/hs105.snc1/4591_90271809329_509954329_1818125_4729552_n.jpg
SBD alloy cambelt idlers, plastic ones tend to explode at high rpm
http://photos-g.ak.fbcdn.net/hphotos-ak-snc1/hs085.snc1/4591_90271814329_509954329_1818126_6730091_n.jpg
cleaned oil pickup on
http://photos-h.ak.fbcdn.net/hphotos-ak-snc1/hs085.snc1/4591_90271819329_509954329_1818127_1975238_n.jpg
SBD alloy fixed tensioner on, stops the cambelt from 'whipping' when your on and off the power violently

picked up the final piston ring today, all fitted and torqued up now... some pics of todays successes

head on, water pump in, jenveys and exhaust mocked up, all head and pullys etc torqued, everything painted, thermostat on & housing on
http://photos-d.ak.fbcdn.net/hphotos-ak-snc1/hs085.snc1/4591_90553039329_509954329_1821891_7394434_n.jpg

another shot while paint was drying on last bits
http://photos-e.ak.fbcdn.net/hphotos-ak-snc1/hs105.snc1/4591_90553044329_509954329_1821892_1875953_n.jpg

2.5" exit but doubt ill hear it over the jenveys!
http://photos-f.ak.fbcdn.net/hphotos-ak-snc1/hs105.snc1/4591_90553049329_509954329_1821893_2930726_n.jpg

shot of SBD hardware and waterpump
http://photos-g.ak.fbcdn.net/hphotos-ak-snc1/hs105.snc1/4591_90553054329_509954329_1821894_7664834_n.jpg

sump on, so finally internals are all sealed up :) ahhh stress over
http://photos-h.ak.fbcdn.net/hphotos-ak-snc1/hs085.snc1/4591_90553059329_509954329_1821895_5843779_n.jpg

tink waiting outside in anticipation =p
http://photos-a.ak.fbcdn.net/hphotos-ak-snc1/hs085.snc1/4591_90553069329_509954329_1821896_4631899_n.jpg

final masked up bits drying off
http://photos-b.ak.fbcdn.net/hphotos-ak-snc1/hs105.snc1/4591_90553074329_509954329_1821897_2725949_n.jpg

everything on, just need a timing belt once i no what im doing about a cover
http://photos-c.ak.fbcdn.net/hphotos-ak-snc1/hs085.snc1/4591_90553079329_509954329_1821898_7810796_n.jpg

ignore the dirty exhaust, just road grime that needs cleaning off, was a bargin at £50 tho! stainless too!
http://photos-d.ak.fbcdn.net/hphotos-ak-snc1/hs105.snc1/4591_90553084329_509954329_1821899_1673568_n.jpg

thats it for the moment folks! hope these pics give you somin to look at! cant wait to get it in but need to start accumulating parts & materials for the next push!

p.s. thought id get stuck into this forum now im going towards the 16v side of things! so if theres any weirdness in the writing up there its cos ive copied it from another forum thread i did!

Cheers!!

Al

[philster]

that looks stunning mate, bet it cost you a few quid

What sort of power are you hoping for?

[alexcrosse]

best thing about vauxhalls is the cheap second hand parts! so its worked out not horrifically expensive, hoping for 150 realistically, standard cam shafts. Nice and drivable though!

[matt]

Welcome to the 5th gear club :lol: . You made a good choice binning the Gay series. Looks very posh the engine keep the good work up and we need more pics :wink:

[cooper_mark]

so what happened to the r1 setup.......???? also what subby did u have with the r1 setup....???

[alexcrosse]

r1 was a pro motive, sold the subby n all quite a few months ago to fund the 8v conversion, i commuted in my mini... R1 wasnt practical really

[cooper_mark]

r1 was a pro motive, sold the subby n all quite a few months ago to fund the 8v conversion, i commuted in my mini... R1 wasnt practical really
if u dont mind me asking how much did u sell the promotive setup for..

[alexcrosse]

Erm... god its a job to remember, 2500 i think? or 2800? one of the two!

Cheers,

Al

[Owen]

Wow, and I thought mine had a few changes! Hats off to you sir! :lol:


Love the attention to detail! :D




P.s. I remember a while back someone was asking if an R1 (or similar) conversion would be suitable/practical for the road... :lol:

[NudgerSS]

Hey Alex glad to see you've made it over from TMF. Just as a note I think you may have trouble with the front crossmember and your exhaust. I had to cut n weld mine so it is hugging the block and it is still tickling it a touch.

John

[pob]

Defo wouldn't fit a standard round nose car.
But should be ok for a Clubman front if the radiator is positioned to the passenger side.

[alexcrosse]

i wreckon... i wont have problem with the cross member cos its different to your nudger, looadddsss of room cos its a clubman allspeed crossmember. Also... think i will be able to fit the same radiator in, if not one of these modern 10mm thick ones. The wideband lambda sensor is to the side so gives extra room for the manifold. At the moment on the 8v the lambda points at 45 degrees to the rad!

Also people... i got a nicely upswept inlet manifold, so i wreckon i will be able to keep standard master cylinders for the time being... any oppinions?

Just been painting the garage floor, one step closer to having the room to dump the lump in!

Cheers for the replys chaps :)

Hopefully line mine up with the 16vminiclub at MITP and dragwars??? if the engines in!



owen: the R1 wasnt practical because mine was a fully stripped out racer! i think i could have made it a bit more livable though, but yer, after a few thousand miles 105db static at 13000 rpm was fun... but annoying on a 45-50 minute commute.
http://www.youtube.com/watch?v=jtU2ZNV98HE
im not advertising another forum on here! lol, it was a favor for a friend of mine!

[NudgerSS]

You're sorted then :)

John

[alexcrosse]

lol, im sure itll go wrong somehow!!!! =p

[caveman]

tink is top,s mate quality build love the attention to detail,but could see a sneaky little turbo in there in the future or are you gonna be happy with standard power,just a thought :twisted: :)

[alexcrosse]

the thoughts there =p keeping a front mounted radiator and plenty of room ontop of the gearbox =p nice gt34 40 will go nicely in that gap! id love to do an all billet bottom end and shove 2 bar through it. 2 years i wreckon!

http://www.youtube.com/watch?v=y8RP54zeNAM

get it sounding like this =p

[caveman]

some were near would do, 3"exhaust straight through that would be awsome

[alexcrosse]

hehe, not without a turbo though, not enough back pressure

[garyshoose]

Welcome to the 5th gear club :lol: . You made a good choice binning the Gay series :wink:



And an even better one not going Kseries may i add :wink: :wink: They're just closset gay's really, but wont admit it to themselves........

Nice to see a 1.6 running jenvy's. 21/2 exhaust sould give it the ideal flow. As Matt says.....welcome aboard.

Gary.

[Owen]

owen: the R1 wasnt practical because mine was a fully stripped out racer! i think i could have made it a bit more livable though, but yer, after a few thousand miles 105db static at 13000 rpm was fun... but annoying on a 45-50 minute commute.
http://www.youtube.com/watch?v=jtU2ZNV98HE
im not advertising another forum on here! lol, it was a favor for a friend of mine!


That sounds mint at full chat! :D

[matt]

Welcome to the 5th gear club :lol: . You made a good choice binning the Gay series :wink:

And an even better one not going Kseries may i add :wink: :wink: They're just closset gay's really, but wont admit it to themselves........

As Matt says.....welcome aboard.

Gary.

Yep those k series Hondas are useless. Honda only good for lawn mowers :lol: :lol: :lol: .

[NudgerSS]

Is that your Mk1 escort as well? Looks like a minter

John

[garyshoose]

Yep those k series Hondas are useless. Honda only good for lawn mowers :lol: :lol: :lol: .



Well i wont argue there coz my neighbour's cutting my grass with one right now 8) Lovely bit of machinery that is, music to the ears........go get me another beer Miss Hoose...... :wink:

[alexcrosse]

cheers for the welcomes guys :)

nudgerSS: no its my dads friends eccy... long story! lol.

Right. electrical mishap with the 8v, certain circuits wernt on relays so it kind of overloading some connections, heated them, correded them, built up resistance etc. Also the fuel pump relay spades were a bit gammy.

So... because im not a fan on the dash i had put in:
http://photos-c.ak.fbcdn.net/photos-ak-snc1/v2165/122/70/509954329/n509954329_1291050_1561.jpg

Everything is stripped out now and all harness covering off
http://photos-h.ak.fbcdn.net/hphotos-ak-snc1/hs106.snc1/4783_94603619329_509954329_1883607_3393004_n.jpg

relax box made and almost fitted now...
http://photos-a.ak.fbcdn.net/hphotos-ak-snc1/hs106.snc1/4783_94603624329_509954329_1883608_1225693_n.jpg
http://photos-b.ak.fbcdn.net/hphotos-ak-snc1/hs106.snc1/4783_94603629329_509954329_1883609_4486530_n.jpg


Clearance on the exhaust, note distance from manifold flange to radiator, plennntyyy of room... i hope =p been busy to measure! :(

[alexcrosse]

right, bit of an update, 8v is still going strong, still scraping together any money possible.

its turning into quite a challenge. Because i want to run jenveys cos of the noise and look of them, its something no one has done before. And tbh the c16xe in a mini has only been done once successfully on the road to my knowledge.

The problem is... because people dont use these in many forms of racing, no touring cars, drag cars or grass trackers, and people dumping engines in novas and corsas go straight for the c20xe finding people in the no is VERY difficult. Luckily, a chap ive found on migweb (vauxhall forum) is a small bore master, and has put me on to a race/rally engine builder called martin bowyer who appears to be a very nice bloke in a barn with ALOT of parts and knowledge.

Im having inlet manifold problems too. Ive got one that is upswept, but it was originally used on a 192bhp c16xe that was ported to the nth degree. On standard cams i dont want to take my head out that much as ill loose my bottom end, sadly the upswept manifolds for c16xe's arnt made anymore, jenvey and sbd havnt even heard to them. So i rang martin and he has one 'lying around' :D hes just checking its all ok and ill have an update on monday for that one.

Also have a bit of a worry about one stem seal i think i might have kinked on the way in, playing on my mind, itll probably be fine, so ill suck it and see, getting the head off and replacing the stem seal is just a days work anyway.

sadly... dads just bought a wreck of a mk1 escort, so im gonna have some problems getting this engine in because of garage space, the whole worlds against me! Im going to aim to do the conversion over christmas now. Get ALL the parts ready for then, and the biggest budget possible for the niggly bits you inevitably need when doing conversions, lol.

thats all for now folks

[kcchan]

Really liking this project. Whats the relay box made from? Looks very smart.

I know all to well what it feels like to be scraping up as much money as you can to finish it though. Im in the same boat.

King

[alexcrosse]

relay box was made from maplins bits, lol. Just went in there to get what i needed. Not sure if itll stay, temped to have it all dash mounted because these things always seem to fail for me! cant wait til tomorrow and have more news on the manifold :razz:

[alexcrosse]

RIGHT THEN! update dot com.

I decide coil overs were a no go for the car, couldnt get the most out of the car with them, spring rates were well out etc etc. So i got everything to go back to standard doughnuts and some decent GAZ adjustable shocks. Upon fitting these however, i put the bolt back in the upper arm to hold the damper which is almost an interference fit, and it went pete tong from there! realised i couldnt get the doughnuts in without taking the upper arms out, and couldnt take the upper arms out without taking the engine out, because unlike the little A series, theres 1600cc of vauxhall in the way.

so...

http://photos-c.ak.fbcdn.net/hphotos-ak-snc1/hs129.snc1/5530_111471959329_509954329_2139250_6454126_n.jpg
out with the old!!

http://photos-b.ak.fbcdn.net/hphotos-ak-snc1/hs149.snc1/5530_111471954329_509954329_2139249_5767877_n.jpg

http://photos-d.ak.fbcdn.net/hphotos-ak-snc1/hs129.snc1/5530_111471964329_509954329_2139251_6721653_n.jpg
and in with the new :shifty:

[clubmanreece]

im confused wat did u use the x20xe for is it the 2 litre head on the 1.6

[cherrybomb]

nice one 16v is theway to go......should be a quick swop with the 8v already in there lol !!!

[alexcrosse]

its a C16XE engine, corsa gsi 1.6 16v, same bottom end as the astra 8v's

UPDATE

Started the day to find it was raining so getting dads escort outside and my mini inside was the first job that took a while! and at the same time ringing a chap to get an inlet manifold, now sorted :D PHEW! relief
http://photos-d.ak.fbcdn.net/hphotos-ak-snc1/hs129.snc1/5530_111898294329_509954329_2144731_2779556_n.jpg
tinks bum hanging out the garage, but the important bits dry :D

http://photos-e.ak.fbcdn.net/hphotos-ak-snc1/hs129.snc1/5530_111898299329_509954329_2144732_8258265_n.jpg
everything out, ready to rock :D

http://photos-f.ak.fbcdn.net/hphotos-ak-snc1/hs129.snc1/5530_111898309329_509954329_2144733_3879148_n.jpg
getting engine lifted into position

http://photos-g.ak.fbcdn.net/hphotos-ak-snc1/hs149.snc1/5530_111898319329_509954329_2144734_4142218_n.jpg
squeezing it in, couple of problems with things in the way like the VR sensor, but once taken off engine slotted right in

http://photos-h.ak.fbcdn.net/hphotos-ak-snc1/hs149.snc1/5530_111898324329_509954329_2144735_7695903_n.jpg
engine in, mounts in, all bolted up nice and tight!

http://photos-a.ak.fbcdn.net/hphotos-ak-snc1/hs149.snc1/5530_111898329329_509954329_2144736_3770254_n.jpg
exhaust manifold fits perrrrrrrfectly :D lots of room left for radiator and clearance for the original front brace bar

http://photos-b.ak.fbcdn.net/hphotos-ak-snc1/hs149.snc1/5530_111898334329_509954329_2144737_3897421_n.jpg
everything coming together

http://photos-c.ak.fbcdn.net/hphotos-ak-snc1/hs129.snc1/5530_111898344329_509954329_2144738_1001882_n.jpg
perfect exhaust manifold

http://photos-d.ak.fbcdn.net/hphotos-ak-snc1/hs129.snc1/5530_111898349329_509954329_2144739_4577919_n.jpg
with front end on ready to go back outside! work done for the day!!!

bad news is.... defiantly need an internal pedal box *looks under the sofa for pennies*!!

[alexcrosse]

right then! yesturday after IMM i went across to a vauxhall GOD and picked up a manifold :) last one he had, took me 3 months to track it down! so mocked it up today, and then carried on with it all. Wiring was the task of the day?!

this is what it started like today
http://photos-d.ak.fbcdn.net/hphotos-ak-snc1/hs129.snc1/5530_111898349329_509954329_2144739_4577919_n.jpg

after ordering an internal pedal box which should be here tomorrow, i got onto taking the master cylinders out and the wiring, so it now looks like this:
http://photos-f.ak.fbcdn.net/hphotos-ak-snc1/hs149.snc1/5530_115145599329_509954329_2187965_5840911_n.jpg
http://photos-g.ak.fbcdn.net/hphotos-ak-snc1/hs149.snc1/5530_115145609329_509954329_2187966_2471110_n.jpg
http://photos-a.ak.fbcdn.net/hphotos-ak-snc1/hs129.snc1/5530_115145619329_509954329_2187968_5589186_n.jpg
http://photos-b.ak.fbcdn.net/hphotos-ak-snc1/hs129.snc1/5530_115145624329_509954329_2187969_7297133_n.jpg

so now its all a big wiring job, going to redo the entire loom myself, it was originally a 93-92 mini or something like that, so the looms a real late carb loom with all the wire ready for injection I THINK (might be wrong). All i can tell, is there far to many wires! lol.

[cherrybomb]

nice one alex looking good, v jealous of all that room in your clubby front !!, what sort of management are you using ? are you planning on doing your own engine loom or a ready made one for your ecu ?

[alexcrosse]

i got one already, it was 2nd hand but a SBD loom with lovely heatshrunk labels! yum yum! Ive got a MBE 967EF to go in, yum yum yum!

loads of room isnt there! plenty for the radiator! thats another job, get that mounted properly.

Cheers buddy

[alexcrosse]

Right then! managed to get some work done on it today :D

Did a few little jobs like plopping on the SBD coilpack and stuff.

pedal box didnt arrive, so i carried on with the wiring loom, found the reason it was so bad, was because of extra wires added after installation, making loops, so it was impossible to unravel.

So took all of it out, removed alot of wires, wrapped it in tackless matt tape, put the rest of the inline fuses into the fuse box. Then put the SBD wiring loom in, shortened the battery connection (was designed for a nova, bit of a stretch to the battery, ive just put mine to the starter motor). I had a hole low down where the shifter cable for the R1 engine used to be, so all looms have been routed through there. Final wiring install was the wideband lambda sensor (innovate LC1) which was simple enough.

Heres some pictures, bare in mind ALL of the wiring in the engine bay is in its finished position (appart from the water temp which isnt routed properly). so its damn tidy IMO :D im quite happy with it :D

http://photos-f.ak.fbcdn.net/hphotos-ak-snc1/hs149.snc1/5530_116186329329_509954329_2201245_6145042_n.jpg
http://photos-g.ak.fbcdn.net/hphotos-ak-snc1/hs149.snc1/5530_116186344329_509954329_2201246_602010_n.jpg
http://photos-h.ak.fbcdn.net/hphotos-ak-snc1/hs149.snc1/5530_116186349329_509954329_2201247_6625110_n.jpg
one for you matt, you were wondering about clearance etc

http://photos-e.ak.fbcdn.net/hphotos-ak-snc1/hs149.snc1/5530_116186379329_509954329_2201252_5330912_n.jpg

jobs for tomorrow : mount the rad, wrap the exhaust, looking at the pics, think i may need to paint the inside of my fg front

[Howie]

Looking very good there, here's mine !

http://i26.tinypic.com/29coy6u.jpg

Howie

[alexcrosse]

very nice, how do you no what cylinder numbers are the coil?

[ludsonline]

Is that not the numbers on the little yellow stickers?

[alexcrosse]

nope, there on the HT leads, no marks as far as i can see on the actual coil, i suppose its gonna be wasted spark so i only need 50% right, lol, but i cant even get that far! oh well, pedal box has just arrived :D TO THE GARAGE *batman theme*

[cherrybomb]

alex, that coil looks the same as mine, the cylinder numbers on mine are at the bottom of the tubes where the ht leads go on just near the main body of the coil, they are small though!!! I had issues with firing mine up, it was'nt the ht's in the wrong place i had wired the terminals at the lt side wrong, if its the same as mine only 3 of the 4 wires are connected, andy

[alexcrosse]

RIGHT THEN!

time for an update.

finally got all of the wiring done except linking the wideband lambda to the ecu, so its just up on a gauge and in a separate logging software at the moment. So the dash is back in :D finally!
http://photos-d.ak.fbcdn.net/hphotos-ak-snc1/hs129.snc1/5530_120162479329_509954329_2255499_1508076_n.jpg
http://photos-c.ak.fbcdn.net/hphotos-ak-snc1/hs129.snc1/5530_120162474329_509954329_2255498_7256453_n.jpg
memo to self, buy a better steering wheel!

Also... GOT THE PEDAL BOX IN! you may have noticed in the other pictures. Ive slammed the steering wheel straight into my privates, and the pedals are now in a brilliant position, before they were a little high so i lowered them. I made the brackets to they could be shimmed at the front to change the position of the pedals.
http://photos-f.ak.fbcdn.net/hphotos-ak-snc1/hs129.snc1/5530_120162449329_509954329_2255493_2007954_n.jpg

All of the fuel lines and the wiring is now installed, and so is the fuel pressure regulator, just need water lines and the engine bay is done!
http://photos-a.ak.fbcdn.net/hphotos-ak-snc1/hs149.snc1/5530_120162464329_509954329_2255496_8039181_n.jpg
http://photos-b.ak.fbcdn.net/hphotos-ak-snc1/hs149.snc1/5530_120162469329_509954329_2255497_4215189_n.jpg

so yer, hopefully go out and buy some water hose tomorrow, went today but couldnt find any big enough, just want to drive it now!

Cheers,

Al

[Owen]

Very nice dude!

[alexcrosse]

thanks owen!

[Owen]

Actually, can I ask how well you thought the 1.6 8v went? Just i'm torn between the 2.0 8v and the 1.6 8v. The 1.6 would be easier for me to do (on my daily, not until current one is finished), but is it worth it?


Sorry for the hi-jack :oops:

[alexcrosse]

thats alrite, 8v was good as a 'gti' car, pulled very well, doesnt pin your head down like the R1 did, but very drivable, and still felt like a mini, handled very well, lighter than the 2l lump. And fits in brilliantly. It was worth it as its my daily driver, if it wasnt my daily driver... i would have chosen my 1430 over it, nothing beats a weber, long stroke and s/c drops

Sorry, i always give jumbled answer =p any more q's just ask mate.

[cherrybomb]

lookin good alex, is that on obp pedal box ?

[alexcrosse]

indeed it is, cheapest one i could find! lol

[NudgerSS]

Bloody Nora Alex you've certainly cracked on with this. I'm still pi55ing about with wiring which is doing my nut in! Me and electrickery don't get on well.

Looks really good you must be well chuffed

John

[alexcrosse]

its coming on well cheers john!

wiring was hell for me, week solid pretty much! but all seems to be working ok, turned it over a little the other day and it made a bang, definatly wanted to go even though there no earth to the engine, and a 270bhp redtop map in the ecu! madness.

exhaust tomorrow, picked up a load of stainless. That fuel pressure regulator didnt work either, so had to get another, never go for the cheap route on ebay!

oh well, id best get some kip before trying the dredded 'welding stainless with a mig welder' tomorrow!

Cheers

Al

[Owen]

thats alrite, 8v was good as a 'gti' car, pulled very well, doesnt pin your head down like the R1 did, but very drivable, and still felt like a mini, handled very well, lighter than the 2l lump. And fits in brilliantly. It was worth it as its my daily driver, if it wasnt my daily driver... i would have chosen my 1430 over it, nothing beats a weber, long stroke and s/c drops

Sorry, i always give jumbled answer =p any more q's just ask mate.



Cheers for that dude! Always good to hear the voice of experience(s)!

[alexcrosse]

RIGHT THEN!

the ebay special fuel pressure regulator didnt work, so i replaced that with a weber alpha one, which was surprisingly cheap, and works! bonus. Ive also fitted the radiator, mounts welded on the front support bar, and one coming across from the cylinder head, although i would like to get one laser cut from a thicker plate soon, something a bit nicer... carbon maybe. Also started to line up the filter, and ive marked out the plate for the filter that ill make out of some carbon sheet i have left. last thing, exhaust, picked up the pipe, seemed to weld alright with the MIG welder, stainless wire and it penetrated really well, was strong enough to withhold the mahoosive explosion that i put through it the other day my turning my engine over with no HT leads (squirting LOTS of fuel into the exhaust) and then putting them in and trying to start it. Resulting in a 2.5" stainless tube, 1.5m long, full of fuel, being ignited, damn it was really loud. Car isnt starting at the moment, struggling to get hold of a base map. not cool!

Anyway, heres the pictures.
http://photos-f.ak.fbcdn.net/hphotos-ak-snc1/hs125.snc1/5370_125401604329_509954329_2325429_6501816_n.jpg
http://photos-g.ak.fbcdn.net/hphotos-ak-snc1/hs145.snc1/5370_125401609329_509954329_2325430_2433867_n.jpg
http://photos-h.ak.fbcdn.net/hphotos-ak-snc1/hs145.snc1/5370_125401614329_509954329_2325431_4558595_n.jpg
http://photos-c.ak.fbcdn.net/hphotos-ak-snc1/hs125.snc1/5370_125401629329_509954329_2325434_7588487_n.jpg
first attempt at welding stainless, meh, could have been worse!

stickers on!
http://photos-a.ak.fbcdn.net/hphotos-ak-snc1/hs145.snc1/5370_125401619329_509954329_2325432_6715746_n.jpg
http://photos-b.ak.fbcdn.net/hphotos-ak-snc1/hs145.snc1/5370_125401624329_509954329_2325433_2266738_n.jpg

[MattG]

looking good. which pressure reg did you buy off ebay that did not work ? as i bought one .. just wondering if its the same :)

Matt

[alexcrosse]

ah, i see you avatar is from my print screen genius? lol.

Erm, it was from... '800bhp' i think.

then i got the adjustable one 1-5bar weber alpha, from this bloke
http://cgi.ebay.co.uk/WEBER-ALPHA-INJECTION-REGULATOR-ADJUSTABLE-0-5-BAR_W0QQitemZ200367850821QQcmdZViewItemQQptZUK_Car sParts_Vehicles_CarParts_SM?hash=item2ea6dac545&_trksid=p3286.c0.m14

[MattG]

ah, i see you avatar is from my print screen genius? lol.

Erm, it was from... '800bhp' i think.

then i got the adjustable one 1-5bar weber alpha, from this bloke
http://cgi.ebay.co.uk/WEBER-ALPHA-INJECTION-REGULATOR-ADJUSTABLE-0-5-BAR_W0QQitemZ200367850821QQcmdZViewItemQQptZUK_Car sParts_Vehicles_CarParts_SM?hash=item2ea6dac545&_trksid=p3286.c0.m14

yea , thought it would make a good avatar :)

i bought this one :

http://cgi.ebay.co.uk/PEUGEOT-106-206-306-307-406-FUEL-PRESSURE-REGULATOR_W0QQitemZ380121530981QQcmdZViewItemQQptZ UK_CarsParts_Vehicles_CarParts_SM?hash=item5881024 265&_trksid=p3286.c0.m14

seems ok at the momment :)

[alexcrosse]

lol, its a good image! Yer, mine was different to that, just didnt let any fuel through atall! had to bite the bullet and get something i definatly knew would work!

[MattG]

had to bite the bullet and get something i definatly knew would work!

i know what that feels like mate

Matt

[alexcrosse]

not good when u have no money! lol

btw, when do i get a passenger ride in your vaux? ;)

[MattG]

not good when u have no money! lol

btw, when do i get a passenger ride in your vaux? ;)

you coming at the weekend ?

i might need a passenger seat first :):rolleyes:

[alexcrosse]

whats happening at the weekend? BMC or something? Im doing a clutch on an R1 mini to get to a show at the weekend... so im probably coming along!

get the seat in there, you dont have to embroider 'Alex' on there, just 'Al' will do ;)

Cheers! =p

[alexcrosse]

right, nowt major doing today, been at work. However, just popped in the garage and played 'pimp my ITG'. Turned out quite nice :D

http://photos-d.ak.fbcdn.net/hphotos-ak-snc1/hs259.snc1/10632_126019014329_509954329_2332915_2057221_n.jpg
http://photos-e.ak.fbcdn.net/hphotos-ak-snc1/hs259.snc1/10632_126019019329_509954329_2332916_8314654_n.jpg
http://photos-f.ak.fbcdn.net/hphotos-ak-snc1/hs259.snc1/10632_126019024329_509954329_2332917_5748026_n.jpg
nothing quite as nice as polished aluminum on carbon fibre :)

thatll do pig... thatll do

[NudgerSS]

Indeed there isn't Al but aren't they supposed to be on the other side? LOL

Poser or what? ;)

John

[alexcrosse]

just checking the PCD and how the 45mm holes lined up too =p and ...getting excited.. over the mixture of polished ally and carbon :o :D

[alexcrosse]

I got a base map and...

:D it runs!


5qh8laoNOMs

number 1: Im not a chav, i just like wearing comfortable jogging bottoms in the garage
number 2: Why does my voice sound so different on camera? lol

Also got all of the water system plumed in, oil pressure gauge running, just dont want to run it anymore until the exhaust is finished, picking up the box tomorrow hopefully, so should be more of a bearable racket. Well please though.

Cheers,

Al

[MattG]

well done !!! its a good feeling ... what ecu you running again ??

Matt

[alexcrosse]

MBE967, which im actually starting to like, once you get to no the features there very flexible.

Best feeling in the world starting a new engine, cant beat it!

[The Mighty Mallott]

Top job, small bore 16v just looks right to me!

[cherrybomb]

nice one alex, you'll enjoy it......small bore 16v def the way to go. glad you got the map sorted

[alexcrosse]

small bore all the way :D

Well, got my muffler today, seems good, alot of work to the exhaust tonite to get it in, had to shorten the back a bit and change the mounts but its in, also got another video. Runs ok, need the adjust the idle, and its running at about 12-13 AFR but tinkering with the initial fuel gain will sort that out best as i can. Only worry is, oil pressure is only at about 2-3 bar... hopefully once it runs a bit more itll sort itself out. only ran it for 30 seconds or so.

anyway! heres pics and a video for you chaps!

http://photos-h.ak.fbcdn.net/hphotos-ak-snc1/hs279.snc1/10632_130058929329_509954329_2383119_2004989_n.jpg
http://photos-a.ak.fbcdn.net/hphotos-ak-snc1/hs259.snc1/10632_130058939329_509954329_2383120_3647041_n.jpg
Cats been helping :)

http://photos-b.ak.fbcdn.net/hphotos-ak-snc1/hs259.snc1/10632_130058954329_509954329_2383121_1487115_n.jpg
http://photos-c.ak.fbcdn.net/hphotos-ak-snc1/hs259.snc1/10632_130058969329_509954329_2383122_8217926_n.jpg
http://photos-d.ak.fbcdn.net/hphotos-ak-snc1/hs259.snc1/10632_130058974329_509954329_2383123_3675485_n.jpg

Now this took a few starts because first: too rich, had to adjust fuel gain. Then the idle was out, so needed a bit of a screw on the throttle bodies, but just held in a little bit of throttle for the sake of the video.
UgfUZMWVouY

and no i wasnt revving it much, 2k max.

[MiniMadGreg.]

Looks good mate, i like it where its out of sight.

[alexcrosse]

cheers greg! the pipe will eventually poke out the back though, but no finisher, just a piece of 2.5" stainless pipe.

right update!

45-50psi oil pressure at idle! :D Just needed to clean out the pressure relief valve! So its looking better. Will probably fall down to 35-40psi when hot, so thats still ok.

Just need to sort out the pedal box plumbing, throttle linkage, and do a spanner check now! sadly were a bit flat out at work at the murment, few stands coming up, and someones R1 mini keeps breaking and i have to fix that...! lol.

Also, might have to put another box in the exhaust... its slightly loud! not even in a chavvy way though! it sounds like an old rally car! real bark to it!

Cheers!

Al

[mininut]

sounds very tappy matey, you sure you're getting oil up to the tappets?

[cooper_mark]

sounds very tappy matey, you sure you're getting oil up to the tappets?
same here....tick,tick,ticking

[alexcrosse]

think its just the camera, remember that there hydraulic lifters, so if there was no oil to the tappets the valves wouldnt open. Sounds good in real life... honest :( lol.

Cheers,

Al

[alexcrosse]

its quietened down quite alot now, oil pressure is about 55psi at idle, very good :D maps well out though! just went home tother weekend to finish it and found i had no parts, so ordered a load and when im next back to the mini ill be able to have a good stint at it. Jobs left to do:
order a TINY alternator
mount brake & clutch reservoirs
run brake & clutch lines
mount alternator & belt etc
map it
drive it like a granny for 1000 miles

:D

[alexcrosse]

had one hell of a cold so went home this weekend. Managed to get a few things done on the car :D but pictures wont be up for 2 weeks until i can get back again!

The reservoirs are in, all 3 into the weber box, so eventually i will put a plate over them so itll look like a standard bulkhead and nothing but engine will be visable. The braided feed lines are in and linked up to the master cylinders, and the clutch line is also linked up, barely visable :)! One problem, cant get it to bleed, the master cylinders getting fluid, and you can hear air pumping in and out of the bleed valve, just need to pressurise the reservoir I think. So in 2 weeks... i should be able to move it around the drive without having to push it! Also moved the caravan connector for the flip front lights etc into where the air intake for the heater used to be, which was 3 birds with one stone, made room for the master cylinder, makes the wire for the flip from completely invisible, and also covers the hole, genius!

Cheers,

Al

oh yer, and it still starts and runs OK, needs a good week of mapping, but starts first turn :D

[alexcrosse]

right, update time i suppose.

All the braided reservoir lines are now done :) and hidden nicely so you cant see them, put the reservoirs in the weber box and eventually will do a plate on dzus fasteners or something to hide everything nicely

http://photos-a.ak.fbcdn.net/hphotos-ak-snc3/hs100.snc3/16741_167656439329_509954329_2712317_1611404_n.jpg
and yes i will weld those old OE holes up one day!

http://photos-b.ak.fbcdn.net/hphotos-ak-snc3/hs120.snc3/16741_167671764329_509954329_2712649_6906758_n.jpg
they sit quite nicely, im pleased with the position, but going to have to tidy up the water hoses to the heater so they go through the bulkhead lower down and you cant see them as much, and im going to soak the expansion tank in bleach because im too cheap to buy an alloy one, "if it aint broke".

http://photos-d.ak.fbcdn.net/hphotos-ak-snc3/hs120.snc3/16741_167673869329_509954329_2712683_4134626_n.jpg
also shot blasted and sprayed the damper mounts, didnt want to buy new ones! im very pleased to see the normal mini setup back on it! coil overs were a baaadddd idea!

http://photos-b.ak.fbcdn.net/hphotos-ak-snc3/hs120.snc3/16741_167656029329_509954329_2712307_2941235_n.jpg
Also going to brase up the bonnet so it doesnt flex and i can have it sat down properly again, looks alot better I think, even though it doesnt let an air out the back, might cut some holes in the back or something. This isnt sitting down properly, havnt adjusted the front pins, and the back ones are off now.

http://photos-b.ak.fbcdn.net/hphotos-ak-snc3/hs120.snc3/16741_167656519329_509954329_2712318_6546895_n.jpg
lowwwwwww-ering needs doing at the back!

http://photos-c.ak.fbcdn.net/hphotos-ak-snc3/hs100.snc3/16741_167668229329_509954329_2712613_1836002_n.jpg
http://photos-c.ak.fbcdn.net/hphotos-ak-snc3/hs100.snc3/16741_167657699329_509954329_2712431_5866540_n.jpg
a nice resin'ed sticker done by martin for me :) going to take off the horrible GB and flag off the back too, tacky, eww!

http://photos-g.ak.fbcdn.net/hphotos-ak-snc3/hs100.snc3/16741_167667854329_509954329_2712611_6347769_n.jpg
and wheel centres for when the 13's go on.

http://photos-f.ak.fbcdn.net/hphotos-ak-snc3/hs120.snc3/16741_167669194329_509954329_2712621_6311271_n.jpg
yum yum yum, horrid wheels though, whos buying them? lol

http://photos-e.ak.fbcdn.net/hphotos-ak-snc3/hs100.snc3/16741_167671769329_509954329_2712650_5241444_n.jpg
looking a little bit cleaner than in other pics

http://photos-f.ak.fbcdn.net/hphotos-ak-snc3/hs120.snc3/16741_167674299329_509954329_2712689_2340526_n.jpg

jobs left:
Alternator
Front brake lines
Mapping

http://www.stomptokyo.com/extras/chuckjones/img/thats-all-folks.jpg

Cheers!

Al

[alexcrosse]

Another update, not been able to do a whole lot of anything recently, to snowed down with everything. But been chipping away on any days ive had.

Ive made a proper hanger system for the exhaust, just need to change the furthest back one which is jubilee clipped with a rubber piece in between. Then cut a section of stainless and welded it onto the back of the can as a finisher, with a sliced cut end.

http://photos-b.ak.fbcdn.net/hphotos-ak-snc3/hs027.snc3/11465_195335934329_509954329_2929308_4787406_n.jpg

http://photos-d.ak.fbcdn.net/hphotos-ak-snc3/hs200.snc3/20760_224373204329_509954329_3051758_4391303_n.jpg

then i decided it was alternator o'clock and got myself down the scrappy for a small alternator search. Managed to get one from a "daihatsu move" or something like that. Then found another from a Subaru Justy, which i hid in the scrappy in case i need another! £20! bargain. There the nippon densos that are sold by companies like SBD as 'race alternators' for £140!... +vat! madness. Also saved 2.5kg

http://photos-f.ak.fbcdn.net/hphotos-ak-snc3/hs200.snc3/20760_224371129329_509954329_3051752_174134_n.jpg

http://photos-h.ak.fbcdn.net/hphotos-ak-snc3/hs200.snc3/20760_224371114329_509954329_3051751_1367270_n.jpg

http://photos-g.ak.fbcdn.net/hphotos-ak-snc3/hs180.snc3/20760_224356094329_509954329_3051673_3546619_n.jpg

So yer, thats where ive got so far, just need to work out why my lambda sensor has decided to always read 21.9 :)

[alexcrosse]

Progress! alternator mount is done (not the tensioner part yet). I didnt want to use the allspeed method because... its garbage IMO! mine broke all the time and its not in a nice position.

it was dark when i took the pics, so sorry for the blurryness!

mount looks like this:
http://photos-c.ak.fbcdn.net/hphotos-ak-snc3/hs180.snc3/20760_235337539329_509954329_3114461_2706229_n.jpg
just tig welded what i fabbed up onto the side of the front engine mount, lots of jigging and measuring and got it straight.

http://photos-e.ak.fbcdn.net/hphotos-ak-snc3/hs180.snc3/20760_235337514329_509954329_3114460_2364506_n.jpg
how the alternator sits now.

http://photos-d.ak.fbcdn.net/hphotos-ak-snc3/hs200.snc3/20760_235337499329_509954329_3114459_7909785_n.jpg
and again

Pics make the car look awful! just was icey and mank, need a tidy up and to add some paint on the side of the block and its a winner. Now the task is to sort out the top alternator mount / tensioner, and the wiring of it.

Cheers,

Al

[NudgerSS]

Alex has your alternator pulley got fewer ribs than the crank pulley? My Denso came with a v-belt pulley so need to get it changed as the one from the Bosch alternator has a different sized bolt so can't swap it over

Cheers - John

[alexcrosse]

yep, my alternators got 3 points, and the main corsa GSI pully has 4 points if that help? I found the same, ones 14mm and the others 16mm it think, measured them and thought this isnt going to work, but to be honest couldnt even get the pullies off!

The entire pully and alternator is off a daihatsu move, so you might be able to get a pully from one of them for cheap at the breakers?

Cheers,

Al

[jayare]

Good to see the dinky alternators fit there - it's where I was hoping to fit mine! Are you going to make the alternator adjustable to tension the belt or add a tensioner roller and have the alternator fixed?

JR

[alexcrosse]

Just about fit yer! ill be putting a tentioner on there, from the thermostat housing i think, in compression so shouldnt hurt anything. I was thinking about a roller but i do have a little bit of adjustability :)

Cheers

Al

[alexcrosse]

Finally got some more work done on the car today! decided to try and finish the mount. I decided to have the tensioner off the same mount, and after lots of sawing, swearing and tig welding... got it finished. Just waiting for paint to dry now.

The tensioner comes off the threaded bar and onto the top of the alternator, and is a standard OEM daihatsu part, good old japs ;)

Tomorrow once its dry i shall update again with it on the car, wired in if i have time!

http://photos-h.ak.fbcdn.net/hphotos-ak-snc3/hs200.snc3/20760_257371639329_509954329_3208619_187732_n.jpg

http://photos-a.ak.fbcdn.net/hphotos-ak-snc3/hs180.snc3/20760_257371654329_509954329_3208620_2224940_n.jpg

http://photos-g.ak.fbcdn.net/hphotos-ak-snc3/hs180.snc3/20760_257371659329_509954329_3208621_3455361_n.jpg

Cheers!

Al

[alexcrosse]

Well got some more done today :) got a final coat of paint on the engine mount come alternator mount. Then trial fitted it and found it JUST cleared the pressure release part of the oil pump, so took some metal out to clear it and resprayed that part. With it all on i modified the existing tentioner arm to remove unwanted material and sprayed that. All on it fits beautifully.

http://photos-e.ak.fbcdn.net/hphotos-ak-snc3/hs180.snc3/20760_259004144329_509954329_3217803_441362_n.jpg

http://photos-h.ak.fbcdn.net/hphotos-ak-snc3/hs200.snc3/20760_259004159329_509954329_3217804_2489064_n.jpg

http://photos-b.ak.fbcdn.net/hphotos-ak-snc3/hs200.snc3/20760_259004184329_509954329_3217805_7886713_n.jpg

http://photos-d.ak.fbcdn.net/hphotos-ak-snc3/hs200.snc3/20760_259004224329_509954329_3217806_1884206_n.jpg

then set to work on a wire guide / guard for the alternator wires and temperature sensor wires. So i made this out of a piece of plate which keeps the wires neet and safe.

http://photos-f.ak.fbcdn.net/hphotos-ak-snc3/hs200.snc3/20760_259004254329_509954329_3217807_1235005_n.jpg

http://photos-a.ak.fbcdn.net/hphotos-ak-snc3/hs180.snc3/20760_259011544329_509954329_3217822_5597909_n.jpg

tomorrows job, finish off the wiring and start figuring out why my lambda sensors packed up!

Cheers,

Al

[alexcrosse]

bit more done today, had lunch with an old friend so didnt have too much time, and then had to take the pictures outside in the dark so yet again i apologize for the quality!

http://photos-c.ak.fbcdn.net/hphotos-ak-snc3/hs180.snc3/20760_260837174329_509954329_3225956_7531305_n.jpg
made up a little loom for the alternator ignition connection and light

http://photos-e.ak.fbcdn.net/hphotos-ak-snc3/hs180.snc3/20760_260837194329_509954329_3225957_3060123_n.jpg
all wired in nicely :) including the alternator light, alternator ignition and alternator live, then temperature sensors

http://photos-f.ak.fbcdn.net/hphotos-ak-snc3/hs200.snc3/20760_260837224329_509954329_3225958_923571_n.jpg
and again :) side of the block always looks rusty in pictures but isnt in real life, im going to have to paint it anyway and get some new bolts for the water pump i think.

http://photos-d.ak.fbcdn.net/hphotos-ak-snc3/hs200.snc3/20760_260837249329_509954329_3225959_912500_n.jpg
got the wires fed through the main bulkhead grommet eventually! interior needs a good tidy up, need to start thinking about it now the cars almost done.

Should have the alternator running tomorrow, then im going to try and calibrate the lambda sensor, if it works "wooo", if it doesnt, i need a new sensor, i think ive broken this one running it cold and rich :(

Cheers,

Al

[MarkLD]

Looking good Alex, good work on the alternator bracket.

Are you running without the cambelt cover, might be worth building a splash guard if you're not.

[alexcrosse]

aye, what do you mean by splash guard? / where?

cheers

al

[MarkLD]

Something mounted off the brace bar up to the underside of the wing (below the bar if you have room) to try and stop stones being thrown into the cambelt. Its probably unlikely but would hate for you to have it happen and trash your motor

[alexcrosse]

yer ive thought about it, everyone seems to think im dancing with the devil but i no a few people personally doing the same thing, and then forum goe'ers like 'insanesweed' off migweb whith a 700bhp astra, that would throw a few pebbles up im sure! Im thinking of doing a plate on the side of the cambelt that follows the outline and protects the inner surfaces.

I keep seeing all these things i want to do now, not gonna be finished til 2020! Just wanna get it on the road so i can build up the 1800 :cool:

cheers,

al

[Marcus Nordblom]

I will also remove mine completely, looks much harder and manly!

[alexcrosse]

lol, good call marcus, anyway:

right, it still runs! and after wiring the alternator (takes me ages to wire things cos i coil and heat shrink everything) i fired it up and got over 14 volts :D Sweeeet, so now all i have left to do is shim the engine and sort out the lambda sensor. Just charging the battery now to do some checks on the lambda sensor. Also cleared out the car, was full to the brim with rubbish from last years shows and the 16v build.

Anyway, heres the video, its a bit jumbled as it was long so cut bits out before putting it on the tube. Also ignore the oil pressure, the senders broken... again...

q78QgrsM9xc

Cheers

Al

[alexcrosse]

Well last weekend i fitted my new lambda controller and sensor which works fine! so cheers rd! I think it mayyy have been my fault the other controller broke, i hadnt insulated the end of an auxillary output wire 0-5v and I think it was shorting, so... my fault, damn!

Has a good weekend anyway, new setup wired in, TPS plug redone as it was faulty, shimmed the engine into it propper position and also dropped some stickers off at camp shonky.

Heres some random weekend pictures:

http://photos-h.ak.fbcdn.net/hphotos-ak-snc3/hs195.snc3/20260_294586484329_509954329_3357151_7797738_n.jpg
http://photos-g.ak.fbcdn.net/hphotos-ak-snc3/hs175.snc3/20260_294588559329_509954329_3357155_7174523_n.jpg
http://photos-e.ak.fbcdn.net/hphotos-ak-snc3/hs175.snc3/20260_294588589329_509954329_3357156_7564579_n.jpg

so getting more dont this weekend, alot of mapping, fixing the hot air blower output for the windscreen, might re route the water lines too. Then it just needs a clean and a good spank ;)

Cheers

Al

[mighty mini jack]

Nearly there dude!

[cherrybomb]

nice one alex, looking good, are you planning a trip to the rolling road ?

[alexcrosse]

cheers, nah trying to get as much mapping done myself, if not all of it. If i feel theres more to come afterwards then yer ill take it to steve greenald

[alexcrosse]

well has a good day on the car. First of all got the new oil pressure gauge put in, nothing like a mechanical one, 60psi cold, which is good, should equate to around 40psi when warm, but only one way to find out!

Also rerouted the heater hoses and the hose to the expansion tank to neaten up the engine bay and inside, and prevent crimping.

http://photos-d.ak.fbcdn.net/hphotos-ak-snc3/hs228.snc3/21560_305032199329_509954329_3389112_2229166_n.jpg
this is how it began, lines going in above the cross member, not cool!

http://photos-c.ak.fbcdn.net/hphotos-ak-snc3/hs208.snc3/21560_305018449329_509954329_3389087_4183696_n.jpg
the lines re routed

http://photos-h.ak.fbcdn.net/hphotos-ak-snc3/hs228.snc3/21560_305032159329_509954329_3389110_5304485_n.jpg
and again

http://photos-b.ak.fbcdn.net/hphotos-ak-snc3/hs228.snc3/21560_305032169329_509954329_3389111_447267_n.jpg
...and again

going to raise the ride height tomorrow, put a brake switch on the pedal box, and try and get it to run a bit better. After that the only jobs left - filter plate, mapping and VSS

Cheers

Alex

[HARBER07]

Looks much better now Al :cool:

Gonna have to sort that rocker cover at some point though haha! :D

[alexcrosse]

aye i no, looking at getting another one that i can shot blast and get powder coated, its really annoying me!

[alexcrosse]

Ok, update from sunday.

Got some more pictures of the car in lights to show the new routing of the pipes
http://photos-f.ak.fbcdn.net/hphotos-ak-ash1/hs424.ash1/23495_307977149329_509954329_3399816_2044178_n.jpg
http://photos-d.ak.fbcdn.net/hphotos-ak-snc3/hs364.snc3/23495_307977154329_509954329_3399817_2923025_n.jpg

got the brake switch fitted and a VERY bad picture taken. Just got a roller switch and works a treat, fabbed up a little bracket to go on the pedal box.
http://photos-b.ak.fbcdn.net/hphotos-ak-ash1/hs424.ash1/23495_307973684329_509954329_3399767_6295330_n.jpg
sorry about the picture, rubbish camera.

got it running, idles fine, map cuts ignition at 1500-2000rpm so need to sort that out, spending this week build up a few base maps and go from there.
http://photos-h.ak.fbcdn.net/hphotos-ak-snc3/hs364.snc3/23495_307973674329_509954329_3399766_7946506_n.jpg

And raised it a little bit to stop the exhaust touching the ground, plus it was sitting on the bump stops. Want to do something about the front end, gap between the wheels and arches is quite big, but that can happen wayyy in the future.
http://photos-a.ak.fbcdn.net/hphotos-ak-snc3/hs364.snc3/23495_307973699329_509954329_3399768_7527707_n.jpg
http://photos-d.ak.fbcdn.net/hphotos-ak-snc3/hs384.snc3/23495_307973644329_509954329_3399764_5283432_n.jpg
http://photos-f.ak.fbcdn.net/hphotos-ak-ash1/hs424.ash1/23495_307973659329_509954329_3399765_4816362_n.jpg

Work for the weekend... vss, filter plate, mapping, drinking

Cheers

Al

[alexcrosse]

Right, weekend work update, few good bits, first of all, all assembled, lights work and is road legal etc, got the reverse switch wired too so now it looks alive!
http://photos-e.ak.fbcdn.net/hphotos-ak-snc3/hs398.snc3/24192_327703744329_509954329_3472302_4496122_n.jpg
http://photos-c.ak.fbcdn.net/hphotos-ak-ash1/hs438.ash1/24192_327703754329_509954329_3472303_1485566_n.jpg
http://photos-b.ak.fbcdn.net/hphotos-ak-ash1/hs438.ash1/24192_327703764329_509954329_3472304_4164509_n.jpg
http://photos-d.ak.fbcdn.net/hphotos-ak-snc3/hs398.snc3/24192_327706579329_509954329_3472307_2158987_n.jpg

Got bored of waiting until ive got enough dwg's to send of for laser cutting, so i just put the carbon filter plate on for now, looks good though, got to be worth atleast 50bhp? lol
http://photos-h.ak.fbcdn.net/hphotos-ak-snc3/hs398.snc3/24192_327703779329_509954329_3472305_4670420_n.jpg

Dash is all back together
http://photos-f.ak.fbcdn.net/hphotos-ak-snc3/hs398.snc3/24192_327703784329_509954329_3472306_7554310_n.jpg
http://photos-e.ak.fbcdn.net/hphotos-ak-ash1/hs438.ash1/24192_327706619329_509954329_3472309_929311_n.jpg

So yer, all is well, the good news is I DROVE IT, 2 whole miles, just low rpm medium load to check for any det in the map (cheers lee303 for the base). Seems nice, all the brakes work, no real problems. Bit of slap and tappets when its cold, but nothing to worry about, dissappears when its warm.

Jobs for this weekend, blue injectors putting on that ive just bought, cambelt cover, shot blast and paint the new rocker cover, go for a drive!

http://photos-c.ak.fbcdn.net/hphotos-ak-snc3/hs378.snc3/24192_327706594329_509954329_3472308_3464133_n.jpg

Cheers

Al

[jayare]

Jobs for this weekend, blue injectors putting on that ive just bought, cambelt cover, shot blast and paint the new rocker cover, go for a drive!

Cheers

Al

Thought you were going to be brave & run without the cambelt cover!

JR

[alexcrosse]

The alternator bracket is causing mass paranoia! Got a few stories of cambelt accidents and no include those without a cover, but it can't hurt! I'll say the stories later, busy... At the pub

[cherrybomb]

well done alex, top build, you'll enjoy it.great engine.....enough to be interesting but still feels something like a mini, Andy

[alexcrosse]

As for the stories, i dont no anyone who has had an accident with a cambelt and getting something in it, except one person (a mate of a mate). who was at a trackday at donnington or somewhere and picked up an alternator belt someone had left on the floor, it flicked up, went through a gap in the cambelt cover he has on it and wrecked the engine. This was done at about 10mph in the paddock. lol.

Cheers cherrybomb, will be reliable and nippy shall we say! not as nippy as the next engine though ;)

[alexcrosse]

Right, full weekend working on the little bits! Hopefully this little circuit will solve the problems ive been having with my tacho, optocoupler circuit.

http://photos-d.ak.fbcdn.net/hphotos-ak-snc3/hs447.snc3/25642_335894439329_509954329_3499950_6133232_n.jpg

Then set to work on the engine bay, first of all attacked the cambelt cover, had to modify it a little bit to clear the subframe but all in now. Also keyed and painted a new rocker cover, and took the horrific yellowness of the oil cap

BEFORE:
http://photos-d.ak.fbcdn.net/hphotos-ak-ash1/hs288.ash1/21560_305032199329_509954329_3389112_2229166_n.jpg

AFTER:
http://photos-b.ak.fbcdn.net/hphotos-ak-snc3/hs447.snc3/25642_335888404329_509954329_3499875_529986_n.jpg

http://photos-d.ak.fbcdn.net/hphotos-ak-ash1/hs467.ash1/25642_335888429329_509954329_3499876_5239342_n.jpg
http://photos-e.ak.fbcdn.net/hphotos-ak-snc3/hs467.snc3/25642_335888499329_509954329_3499878_8159234_n.jpg
http://photos-h.ak.fbcdn.net/hphotos-ak-snc3/hs467.snc3/25642_335892419329_509954329_3499938_5116451_n.jpg
http://photos-b.ak.fbcdn.net/hphotos-ak-snc3/hs447.snc3/25642_335892449329_509954329_3499939_4600952_n.jpg
http://photos-e.ak.fbcdn.net/hphotos-ak-ash1/hs467.ash1/25642_335892499329_509954329_3499941_8263486_n.jpg

Getting these tested and new seals put in this week, better spray pattern... and closer to the base map i have!
http://photos-f.ak.fbcdn.net/hphotos-ak-ash1/hs467.ash1/25642_335894449329_509954329_3499951_1712353_n.jpg

Cheers!

Al

[MiniMadGreg.]

The transformation is just great. Really made it standout and not look 'tatty' anymore. Great build mate. Keep it up :)

[alexcrosse]

cheers dude, i shall! driving time in 2 weeks

[HARBER07]

Bloody hell Al that looks loads better! Nice one!

[jayare]

Almost there! Where did you have to mod the cambelt cover? All looks intact in the photos,

JR

[alexcrosse]

Alrite jr, yer almost there :D

yer interesting one that mod... i think think 'the matt' or nudger had to do anything which is just do to the positioning of the engine i guess, mines further back with more of a lean, couldnt be arsed to get the engine crane out so just cut it. I modded it around the water pump, you can see 4 pop rivits where ive created a couple of aluminium plasters. Basically the 16v cam cover goes around the outside of the water pump retaining bolts, where as the 8v one goes on the inside, so i just spliced a bit of the 8v one onto my 16v one and bolted her on! then also had to cut some out the back where ive routed my power cable from the alternator.

Cheers

Al

[NudgerSS]

I could do with taking a bit of my cam cover to be honest. It just tickles up against the tower on the subframe. Just not got around to it thats all.

Cheers - John

[cherrybomb]

nice job on the cam cover alex, i'm still running a standard steel round nose front, you look like your engine is much nearer the passenger side than mine, are you using allspeed driveshafts, thats what stops me moving mine to the left. Wish i could as there is no chance i can get the cambelt cover off with the engine in the car !!!

[alexcrosse]

yer using allspeed driveshafts, tired to budge it as much to the passenger side as possible but only so much you can while keeping a safe amount of float in the CV's.

I can get mine off and its pretty much on the subframe (damn close). Do get worried about if the engine moves when under torque... lol. you get any knocking or damage to the subframe?

[cherrybomb]

i have no movement to enable engine to hit frame, left cv joint v.close to frame, can get a very light rub on that. closest point is cambelt cover on rh inner wing . tight all round though in a round front thats not removable !!
i think the top (4th) engine mount stops most movement.....

[alexcrosse]

i have no movement to enable engine to hit frame, left cv joint v.close to frame, can get a very light rub on that. closest point is cambelt cover on rh inner wing . tight all round though in a round front thats not removable !!
i think the top (4th) engine mount stops most movement.....

Yer i spose it is pretty solid, oh well only one way to find out i suppose! Might put a bit of lead in the tight places with a small gap to see if it dents the lead atall when under load.

[alexcrosse]

Update time, got these injectors back after cleaning and testing. All balanced with each other perfectly. So spent today putting them in.

http://photos-f.ak.fbcdn.net/hphotos-ak-ash1/hs467.ash1/25650_365432474329_509954329_3577189_7795330_n.jpg

Then it refused to run properly, realized it was a bad plug, lots of cold starts running very very rich ruined it. So bought a new set and put them in... win! started poifectly.

The went for a spin! Had a bit of a worry, it was using alot of water once i got back from the drive, then realized it was just filling the rad properly once the thermostat opening. Filled it back up with water and went for another drive.

Pulls well, maps still a bit out but alright for running in. up to 4000 at half throttle it pulls like a train, nice to have some serious power back after the 8v period. And also nice to get back behind the wheel of a mini, nout else compares ;) lol.
9pjAGJrzyro
and yes, thats my happy face...

Cheers,

Al

[revingtosh]

Alright buddy - can i ask a favour?

Im thinking of going the X16SE route eventually, but im considering going for some downdraught ITBS on a custom manifold.

Can you tell me the distance between the inlet side of the head and the bulkhead when you get a minute? Im just wondering if there will be room for ITBs and the existing Allspeed clutch and brake mechs.

Cheers,

Mike

[alexcrosse]

revingtosh: X16SE? whats that? Ill measure it when i get a moment, ITBs do fit in with the allspeed setup, rob hall had his X16XE mini.

Update:
Right, after i spent last weekend driving around i found a few things i needed to do. First of all... the battery was ruined, only lasted for 1 start :( so i bought a new one from halfords. Also needed something to help me hear detonation when driving around mapping the thing, hear it over the throttles, wind and general racket so made some det cans:

http://photos-g.ak.fbcdn.net/hphotos-ak-snc3/hs476.snc3/26084_380585924329_509954329_3667104_5240160_n.jpg

http://photos-e.ak.fbcdn.net/hphotos-ak-ash1/hs476.ash1/26084_380585944329_509954329_3667107_1695429_n.jpg

obviously still need a T piece for them! lol

Apart from that, need a new crank pulley, mine wasnt exactly a good fit, bit of a wobble, i think its been overtightened at some point (according to lee, lol) so going to find a new one. Also, oil pressure is good when driving, 25psi when hot at idle... but for piece of mind im going to put a new pump, housing and release valve on it (full assembly jobby). Then back out driving again :D hoping to have a day off during the week to get the oil pump done! then santapod next weekend!

Cheers,

Al

[cherrybomb]

hi al, i would'nt worry bout the oil presure, that sounds fine, both the x16xe's i've had in mine are the same 25psi when hot at idle, soon as you add revs upto 60psi +, this is using 10/40 semi synth oil std vauxhall spec.

save youself some time and drive it............!!!!

[alexcrosse]

thats good news, think im using 10/40 mineral :S halfords finest standard injection engine oil :p

Just not nice watching it drop towards 20 every time you come to a stop! why you had 2 engines then?

[cherrybomb]

1st one i had needed stem seals etc like they all do and was a proper smoker ! the 2nd one i got was only £50 once i had sold the ancillaries and had new belt,water pump,stem seals and head gasket on it, cheaper than fixing the 1st one .....I was concerned at oil pressure too at first, i asked a few guys on the vaux forums, they are all the same...some of the vaux guys started to use a 20/50 if it dropped too much when hot.

[alexcrosse]

Right, today was oil pump day. The threads in the old one were knackered where the sump went on, and it was also old, so wanted it replacing! first job was to strip it all down. Dropped the sump and realized that the engine needed to come out so i could actually get the sump off and get to the two bolts that hold on the oil pick up pipe.

http://sphotos.ak.fbcdn.net/hphotos-ak-snc3/hs035.snc3/12309_386940334329_509954329_3814176_1924916_n.jpg

Did so, and got the old pump out

http://sphotos.ak.fbcdn.net/hphotos-ak-snc3/hs035.snc3/12309_386940344329_509954329_3814177_3267978_n.jpg

Still hovering put the new pump in, nice n shiney :)

http://sphotos.ak.fbcdn.net/hphotos-ak-snc3/hs015.snc3/12309_386940354329_509954329_3814178_4898408_n.jpg

And got it all back together

http://sphotos.ak.fbcdn.net/hphotos-ak-snc3/hs015.snc3/12309_386940364329_509954329_3814179_2110536_n.jpg

http://sphotos.ak.fbcdn.net/hphotos-ak-snc3/hs035.snc3/12309_386940369329_509954329_3814180_4024354_n.jpg

Havnt had a chance to run it yet, mainly because i snapped a bit of the expansion tank off... so cant fill it up with water until i fix that tomorrow morning. Hope all is well!

Cheers,

Al

[cookie4343]

Whens v6 lol.

[alexcrosse]

ssshussshhh! *cough* 240bhp *cough*

[tinxy]

ssshussshhh! *cough* 240bhp *cough*

hello:cool:

[alexcrosse]

forgot to mention what happened on the sunday, got all the last bits back together and it fired up after half a revolution, LOL.

http://sphotos.ak.fbcdn.net/hphotos-ak-snc3/hs516.snc3/27105_387720684329_509954329_3834903_6344881_n.jpg
nice tidy alternator

http://sphotos.ak.fbcdn.net/hphotos-ak-ash1/hs496.ash1/27105_387718859329_509954329_3834840_3391513_n.jpg
nice tidy engine bay.

Fixed the expansion tank by putting a little sleeve in and epoxying it, itll do for the time being until i find something a little bit tidier for it. Surely a tig welded aluminium one should be worth atleast 20bhp? lol.


got a few jobs done this weekend too (well, sunday). Got the sidelights working, just needed to spray out the pins on the caravan connector a bit, lots of swearing and hitting things working it out until dad walked past and just said 'widen those pins' lol. Hate it when that happens. Anyway they work a treat now. Also gave it a big old clean out so is nice inside and out, you cant polish a turd but you can roll it in glitter. Finally i fixed the leakey exhaust by actually putting a clamp on it, problem solved!

Because my MOT would expire on the 5th i decided to take it in for a test (i had a presentation in sheffield to do so had to get my dad to drive it) and SUCCESS! ITS PASSED!!! no advisories ofcourse =p

next jobs are to helicoil a knackered thread for the cam cover, and PTFE the oil pressure sender and thats it!

[alexcrosse]

run in! update when i get a propper chance,

but for now heres a video with extremely bad sound and no grip!

zLLcjGWHSzk

[MarkLD]

Very nice Alex, forgot how loud the TB's can be. Is that the Mollington Juction on the Banbury Road?

[alexcrosse]

indeed it is, im a cropredy lad! camera couldn't handle the TB's sadly!

[MarkLD]

Will have to get the car up and running and arrange that meet up.

[alexcrosse]

need to come and see your cage anyway! didnt realise yours wasnt running, what have you broken?

[MarkLD]

I had read you pm, just hadn't got round to replying yet, lol.

Nothing broken, just improvements. (crosses fingers)

[alexcrosse]

please say the words "anti lag", lol

[alexcrosse]

Hit 2000 miles today, still running well, clean and pulls. still need to take more fuelling out of lower map sites, getting around 35-40mpg but think if i take more fuel out on lower load cruising sites ill get it to 45-50mpg. That 35-40 is not eco driving either, its regular trips to 7750rpm on hitting the rev limiter and raping it into the next gear to spin up the wheels! Next job is handling before further engine developments. Full miglia cage is coming early next week, the engine is ripping the shell to bits i think... doors arnt shutting as well as they used to! Then going to work on the rear end. I have discovered that some people who have told me "just get the front geometry set well, the back only follows" are completely wrong! lol.

16v daily driver ftw!

[cherrybomb]

hi alex, sounds good, 2k miles !!!!! dont think i have done that in 2 years ...... I set up mine all 4 wheels and it made a difference but still struggled with inside wheel spinning under hard acceleration and understeer. The thing that made a huge difference to the handling was a rear anti-roll bar. It reduced body roll and understeer massively, i should have got one years ago...
Also have you cammed yours ? not much point taking mine over 7k revs..
hope this helps, andrew

[alexcrosse]

nope, havnt cammed it, but pulls hard still at 7750 so i take it there, good changing gear and it drops straight onto peak power again. I dont get too much understeer, lots of lift off oversteer though, definatly going for a rear ARB when possible, so much to sort out though!

[NudgerSS]

2000 miles? Geez sounds like you're getting some use out of it Al. Really need to get my arris in gear n get mine Tested so I can get some use out of it this summer. Apart from the one naughty jaunt down the road I've just been thrashing it up and down the backlane :(

John

[alexcrosse]

cars been going ok, only problem being a snapped throttle cable, easily fixed! getting on to 3000 miles now :D

Had a great weekend at avon park, drank my own body weight in cider. The car managed a 14.6 second quarter, 60ft in 2.3 seconds. Thought this was very good considering it is full weight really, with falkens on the front at 28psi! LOL. Itll easily see 13's with yokos on the front i think.

Bought some more bits for the car recently...
First of all:
http://sphotos.ak.fbcdn.net/hphotos-ak-snc4/hs055.snc4/35094_415540179329_509954329_4487440_4309187_n.jpg
roll centre miglia weld in cage, should do the trick! just gotta get it in :S

And:
http://sphotos.ak.fbcdn.net/hphotos-ak-snc4/hs194.snc4/38039_415521934329_509954329_4486958_3596645_n.jpg
http://sphotos.ak.fbcdn.net/hphotos-ak-snc4/hs075.snc4/35136_415534454329_509954329_4487371_823400_n.jpg
motordrive fibreglass bucket seats with securicon 4 point 3" harnesses :D

Time to start cutting some weight!!!

[Joah]

Time to start cutting some weight!!!

By putting the big heavy rollcage in! ;) (who needs safety) good times at avon though well done! :)

[alexcrosse]

Cheers, will be better times once i got some grip, but its a track weapon, not for driving in a straight line =p

anyway, cages = faster surely? lol there in racing cars and all that stuff =p, nah its just pulling the car to pieces at the moment, sure its put a couple of cracks around the floor / bulkhead.

[cherrybomb]

great times alex, i ran a 16.0 with road tyres at full pressure, wish i had taken my yoko 48s now.......are you using the diesel box ? I am and still struggled with wheelspin all the way through 2nd....Your times are great though, I am running a rollcage and full interior and full steel front, should'nt have cost me a whole second though !!!! Andrew

[alexcrosse]

yer i was running diesel box, has a pretty heavy interior atm, not purpose lightweight! Must be driver skill then? LOL! It would spin through 2nd and 3rd, and spins through 4th on road sometimes, but just felt the throttle through the revs to prevent any slipping.

It was also with a very very rich map, alot more ignition that could go in and fuelling that could come out. Took alot of care building the engine, got a pretty high CR tbh after some block skimming ;) but thats all top secret =p I feel i can put alot more power down given decent tyres and less camber, IMO i could get my car into early 13's on this engine.

You coming to MITP?!

Cheers,

Al

[cherrybomb]

Nice one 13's from a 1600 is strong I was hoping to get low 15's On the right tyres and no luggage lol.my reaction times were both 0.6secs so not much to be had there. Can't do mitp as will be on honeymoon !!!!! cheers andrew

[alexcrosse]

reaction times shouldnt count towards your final recorded time on any RWYB event or anything but FIA top fuel finals! LOL. I wreckon 12 seconds is see-able with a 1600 tbh mate. The weight is awesome, along with the power delivery, if i can see 200bhp from a 1600 which is proven easily possible 12's will come.

But... its a track car, not a drag car! lol

Congrats on the marriage-ness then pal!

Cheer, Al

[alexcrosse]

Reeeeto

Had a ruined thread in one of the camshaft caps (the thread is for a bolt that holds the camcover on) so took the cover off and helicoiled the cap, problemo solved!...

...but while the camcover was off it was looking a bit tired, and also had some bosses and clips i didnt want, so cut and dye grinded them off, painted it, shot blasted the bolts to silver them up again, and 400gritted the washers to shine everything up :)

http://sphotos.ak.fbcdn.net/hphotos-ak-ash2/hs084.ash2/37548_419885609329_509954329_4597842_6665490_n.jpg
http://sphotos.ak.fbcdn.net/hphotos-ak-ash2/hs084.ash2/37548_419885614329_509954329_4597843_3586755_n.jpg
http://sphotos.ak.fbcdn.net/hphotos-ak-snc4/hs184.snc4/37548_419885619329_509954329_4597844_3109386_n.jpg

bonnet is to be fixed tomorrow, woop

[MarkLD]

Looking very good and glad everything is running OK. I keep seeing you out and about, if you see a black Focus ST with its headlights on then give me a wave.

[alexcrosse]

will do mate! if i can see over my flexing bonnet!

[alexcrosse]

Right then! southern mini days show was a good laugh, however took a mate (mike) out for a blast on the third day and heard a clunk click whiiinneneee, so pulled over to investigate, saw a clip had undone on the cambelt cover, so thought nothing of it, clicked it back in and carried on, whine gone! After taking dan and some others out on the sunday i heard a bit of a strange noise coming from the cambelt cover so pulled the top off to investigate, looking down into it saw this had happened to the cambelt:

http://sphotos.ak.fbcdn.net/hphotos-ak-snc4/hs232.snc4/38953_424667714329_509954329_4726900_5576032_n.jpg

not nice, on pulling the whole cover off found a bolt and a piece of cylinder head in the bottom by the crank cambelt pulley. Turns out the bolt was one which held the cam cover on, it had come undone, gone into the inlet cam pulley, chipped the cylinder head (no propper damage), then the bolt and cylinder head piece ran inbetween both cam pulleys and the belt, then to the bottom, in doing this caused the damage to the belt and some big dents in the pulleys as seen below (after id filed the flat in a field in kent!)

http://sphotos.ak.fbcdn.net/hphotos-ak-ash2/hs112.ash2/38953_424667709329_509954329_4726899_6686870_n.jpg

Hard to see, but there is damage to most of the teeth, anyway, in a field, did the cambelt change, filed the pulleys til they were safe and started it up, could see the inlet cam pulley had a bit of a wonk on while spinning due to the bolt going behind it and bending it, but thought aslong as i drove at low revs on the way home it would be fine. Must say though, i got a new bolt from smithys bits while at the show he donated to the cause, so thanks for that :) alot of people that day like mike, martin, neil, burney and loads more who helped save my bacon!

http://sphotos.ak.fbcdn.net/hphotos-ak-snc4/hs304.snc4/40550_424667174329_509954329_4726861_1256446_n.jpg

Above is the bits i found in the cambelt!

Today went to the scrappy to get some more pulleys, got them, then screamed at home when i realised that one of the timing lugs had snapped off the exhaust cam pulley, so had to get it on the lathe and get rid of them.

http://sphotos.ak.fbcdn.net/hphotos-ak-snc4/hs112.snc4/35974_424667384329_509954329_4726882_1076909_n.jpg

Heres the two pulleys i bought from the scrappy, with one broken lug :(

http://sphotos.ak.fbcdn.net/hphotos-ak-ash2/hs138.ash2/40247_424667619329_509954329_4726889_4382016_n.jpg

Got it all centred up with the gauge to get the best balance.

http://sphotos.ak.fbcdn.net/hphotos-ak-ash2/hs138.ash2/40247_424667634329_509954329_4726892_8198135_n.jpg

Lugs just ended off, then obviously face them off nice and flat, better surface finish.

http://sphotos.ak.fbcdn.net/hphotos-ak-snc4/hs258.snc4/40247_424667644329_509954329_4726894_4891920_n.jpg

All sprayed up (light coat of zinc and black) and the lugs faced, sprayed the inlet pulley too, but has no timing lugs.

http://sphotos.ak.fbcdn.net/hphotos-ak-snc4/hs258.snc4/40247_424667654329_509954329_4726896_6156547_n.jpg

With bolt and washed (shot blasted bolty loveliness :D) And a sneeky look at my massive trumpets in the background =p (cheers lee)

http://sphotos.ak.fbcdn.net/hphotos-ak-snc4/hs278.snc4/40247_424667659329_509954329_4726897_1079844_n.jpg

All on, spin true... then found that the water pump that id bought (old one needs replacing as the bolt when into it a ruined the bearing) was a nasty copy, and not man enough for the 16v, worried about cooling issues and high revs, so i shall buy a new one tomorrow morning.

On the good side... this turned up today:
http://sphotos.ak.fbcdn.net/hphotos-ak-snc4/hs092.snc4/35974_424667374329_509954329_4726880_3020225_n.jpg
http://sphotos.ak.fbcdn.net/hphotos-ak-snc4/hs092.snc4/35974_424667379329_509954329_4726881_5705321_n.jpg
http://sphotos.ak.fbcdn.net/hphotos-ak-ash2/hs052.ash2/35974_424667369329_509954329_4726879_3023492_n.jpg

Cheeeeeeerrrrsssss,

Al

[Joah]

shame about the bolt but good to see a quick repair!!

whats the rest say on the mug in the second photo? :P

[alexcrosse]

it sayes "another fucking crisis" but i think the crisis is in yellow so dont come out :( didnt realise it was in shot or owt!

[alexcrosse]

seemed to go ok at santapod, ran 14.5 on the rubbish falkens again, only did 3 or 4 runs, with my luck at the moment i didnt want to push it too much! Dads escort has gone off to the paintshop which means... ive got a garage for 2 weeks... time to fire up the compressor and get the welder warmed up!

[alexcrosse]

Right then... after talking to a few 16v peeps at santapod and having a think, ive decided the mini is to be a purposeful sprint and hillclimb car, but still road legal for class and trackday reasons :)

So... im pushing myself to get this cage done. Got it in the garage, unwrapped everything, the writing marking each tube was on the outside, so ive listed each tube, given each one a letter, then put a morse code reference on the inside of each tube so im not free to clean them, and paint them, and ill still no where each tube goes :D win!

http://sphotos.ak.fbcdn.net/hphotos-ak-snc4/hs388.snc4/45092_428989684329_509954329_4832825_1857137_n.jpg

hopefully... there will be some more interesting updates over the next coupla weeks :)

[alexcrosse]

ended up moving to london, working in essex, and then working in belgium, so everything got put on hold... until now!

Got myself some space with a coupla mates in essex; so now have LOTS of room :D so celebrated by buying some brakes:

http://sphotos.ak.fbcdn.net/hphotos-ak-snc4/hs1129.snc4/149181_466671279329_509954329_5530659_1637758_n.jp g
http://sphotos.ak.fbcdn.net/hphotos-ak-ash2/hs605.ash2/155698_466671539329_509954329_5530662_5109871_n.jp g
http://sphotos.ak.fbcdn.net/hphotos-ak-snc4/hs987.snc4/76052_466671854329_509954329_5530664_7800900_n.jpg
http://sphotos.ak.fbcdn.net/hphotos-ak-snc4/hs1144.snc4/148600_466672104329_509954329_5530666_1361963_n.jp g

gonna get some wheels next, and soon as i get a free weekend ill start replacing the heelboard and getting the shell sorted :)

[alexcrosse]

So yer... moved into the new unit now, finally got to work on the mini, turns out the scuttle is not happy, heelboard isnt as bad as id thought; though awkward, and the rear arches have gone inside. However, im going to tub and turret it, the scuttle is going to be composite, and the heelboard just needs attacking. Hoping to get the bodywork over asap, I hate it.

Oh yer, and theres some holes in the back that need patching.

http://sphotos.ak.fbcdn.net/hphotos-ak-ash2/hs447.ash2/72079_488971434329_509954329_5850091_8370078_n.jpg
http://sphotos.ak.fbcdn.net/hphotos-ak-snc4/hs933.snc4/74666_488971719329_509954329_5850095_7820565_n.jpg
http://sphotos.ak.fbcdn.net/hphotos-ak-snc4/hs1355.snc4/162702_488971984329_509954329_5850096_7310270_n.jp g

back in the garage tomorrow, with a spot weld drill, an angle grinder, and alot of anger,

Cheers,

Al

[alexcrosse]

Right, onto the rot fest...

heres the OS Turret
http://sphotos.ak.fbcdn.net/hphotos-ak-ash1/hs793.ash1/168328_489771104329_509954329_5860533_7455538_n.jp g

Under where the washer bottle was
http://sphotos.ak.fbcdn.net/hphotos-ak-ash1/hs778.ash1/166822_489771374329_509954329_5860535_4846245_n.jp g

This came out... beam'o'clock
http://sphotos.ak.fbcdn.net/hphotos-ak-ash1/hs780.ash1/167017_489771839329_509954329_5860544_8341304_n.jp g

Valance came off, was horrifically rotted, I shant be replacing this ;)
http://sphotos.ak.fbcdn.net/hphotos-ak-snc6/hs047.snc6/167781_489771549329_509954329_5860538_3388727_n.jp g

Quite a substantial hole I had to cut on the side of the heelboard! Was a nightmare to cut out, taken additional material out also, such as the seam between the rear bench, side section of rear bench, and side bucket bit. As I chopped out the rear buckets theres no need for it. To be honest I'm not too worried about any stiffness within the shell, aslong as its straight. The cage will be the structure of everything, shell purely cosmetic.

http://sphotos.ak.fbcdn.net/hphotos-ak-snc6/hs012.snc6/166272_489770969329_509954329_5860531_3904106_n.jp g

looking into the car through the hole

http://sphotos.ak.fbcdn.net/hphotos-ak-ash2/hs009.ash2/33811_489771699329_509954329_5860542_1561080_n.jpg

heelboard fix in place

http://sphotos.ak.fbcdn.net/hphotos-ak-snc4/hs1365.snc4/163711_489772504329_509954329_5860561_2267702_n.jp g

Right... genuinely sorry about the pictures! I had a crap light and only took pictures at the end of the day, lol. It should all look more solid soon.

Cheers,

Alex

[Ferrina]

Great build diary fella and lovin' the sound of those T/B's. Good luck fixing the bodywork.

[alexcrosse]

Lol, cheers pal, I hate it this rust removing bit!

[HARBER07]

Shed!! Scrap it!!

[Burnard]

You keeping the 850 badge then?

rust is a pita, but its part of owning a mini.
fibre glass is the future me thinks, definatly less to worry about.

[alexcrosse]

meh, aslong as I get all the rust out im happy!

Tom - just because your becoming a pro at scrapping shells / projects theres no need to show off ;) :p

[HARBER07]

lmao

All those shows spent near Shifty hasn't done me any good.

[alexcrosse]

Right, found a light today! excellentay!

Plate put in the bottom of the wheel arch and heel board OS fixed :)
http://sphotos.ak.fbcdn.net/hphotos-ak-ash1/hs740.ash1/163287_490459039329_509954329_5868883_1765896_n.jp g

Again, but top plate can be seen here too, notice no more horrible seam from the rear buckets :) must have saved atleast 10 grams, lol.
http://sphotos.ak.fbcdn.net/hphotos-ak-snc4/hs1338.snc4/163069_490459084329_509954329_5868884_7710439_n.jp g

Close up, everything ready for the final floor fix, then that corner will be pretty much done :) Ignore my welding there... had to get used to a new welder and that was the first squeeze, lol.
http://sphotos.ak.fbcdn.net/hphotos-ak-snc6/hs026.snc6/165668_490459129329_509954329_5868886_883001_n.jpg

Bit of CAD... can you tell what it is yet?
http://sphotos.ak.fbcdn.net/hphotos-ak-ash1/hs740.ash1/163224_490459244329_509954329_5868888_6465186_n.jp g

Ready to go in, just got to weld prime it and drill plug welding holes and on to a winner :)
http://l32.sphotos.l3.fbcdn.net/hphotos-l3-snc6/hs026.snc6/165645_490459189329_509954329_5868887_183112_n.jpg

More tomorrow, sorry for the boring bodywork pics =p

Cheers,

Al

[dig-mini]

Its ok For me I like to see it all and I must say your doing a great job. I'd love to see this if ever you go to show or some where a bit closer up my way.
Cheers and good luck Craig

[alexcrosse]

lol, yer ill be the drunk one at riv run

[HARBER07]

Looking good Al. Maybe it can be saved after all :lol:

[alexcrosse]

maybe tom, maybe! Hopefully that corner will be done tomorrow morning and I can start attacking the other side, will be another day of chopping rubbish out I guess :(

[HARBER07]

You fully equipped with a plasma cutter?

[alexcrosse]

sadly no longer, but my new favourite toy is a pneumatic body saw, 1.5" hacksaw like blade, tis like a knife through butter =p

[HARBER07]

Still better than pissing about with a grinder and getting sparks in your face!

[alexcrosse]

if its working well it will make do about 1/4 - 1/2" a second, with only a 0.5mm wide blade and very little mess. Sometimes a pneumatic cutter or grinder is unavoidable though!

[alexcrosse]

Right-oooooo

Got this more done yesturday (didnt update last night, was far too drunk).

OS mount is now solid and modified to remove the bucket seam :)
http://sphotos.ak.fbcdn.net/hphotos-ak-snc6/hs011.snc6/166125_491380189329_509954329_5883875_1762577_n.jp g

And view from under
http://sphotos.ak.fbcdn.net/hphotos-ak-snc6/hs045.snc6/167517_491380239329_509954329_5883876_7149276_n.jp g

This is what I found the other side after getting rid of some anger with a wire brush. Because of where the thin metal and rust was I found I will need to replace near enough the same amount of metal as the other side, plus, I had a feeling there would be rust between the innersill / floor and outer sill so wanted to cut a chunk out anyway =p
http://sphotos.ak.fbcdn.net/hphotos-ak-snc4/hs069.snc4/34811_491379989329_509954329_5883870_7788870_n.jpg

This is what I found after getting excited with the bodycutter
http://sphotos.ak.fbcdn.net/hphotos-ak-ash1/hs756.ash1/164730_491380024329_509954329_5883871_6071272_n.jp g

Pretty much ready to start reconstructing now
http://sphotos.ak.fbcdn.net/hphotos-ak-snc6/hs067.snc6/167773_491380079329_509954329_5883872_106204_n.jpg

quite pleased now, should have the healboard rust issues resolved by monday, then can start attacking the boot floor issues, and put new valance quarters on.
http://sphotos.ak.fbcdn.net/hphotos-ak-snc4/hs1387.snc4/163957_491380299329_509954329_5883877_8331947_n.jp g

There is a very small light at the end of a very long tunnel!

Cheers,

Al

[alexcrosse]

Right, im feeling a little less delicate today so went to the garage and stayed there! I apologise in advance for both the poor pictures and content of them, lol.

Managed to get the heelboard fixed, the seam removed and top panel replaced. Just have to put a little bit of floor back in and thats the healboard done :) ...from inside:
http://sphotos.ak.fbcdn.net/hphotos-ak-snc6/hs033.snc6/166372_492096074329_509954329_5901058_7796405_n.jp g

from inside again
http://sphotos.ak.fbcdn.net/hphotos-ak-snc6/hs015.snc6/166548_492096144329_509954329_5901060_6386352_n.jp g

from outside
http://sphotos.ak.fbcdn.net/hphotos-ak-snc4/hs1334.snc4/162683_492096259329_509954329_5901069_8062543_n.jp g

Now I need to start looking towards sorting the boot floor, valance corners, tubs, turrets and diffuser!

Cheers,

Al

[alexcrosse]

Another lonely update!

Got the other side of the heelboard all fixed (floor finished)
http://sphotos.ak.fbcdn.net/hphotos-ak-snc4/hs1335.snc4/162768_492888534329_509954329_5913587_5024122_n.jp g

Need to fettle back the edge of the seat at some point! But its pretty low on my list of prioritie
http://sphotos.ak.fbcdn.net/hphotos-ak-snc4/hs1373.snc4/164571_492888669329_509954329_5913590_5744230_n.jp g

Very pleased to have it done, horrible area to work on!
http://sphotos.ak.fbcdn.net/hphotos-ak-snc6/hs048.snc6/167848_492888474329_509954329_5913586_594776_n.jpg

So celebrated with some mindless youthful graffiti
http://sphotos.ak.fbcdn.net/hphotos-ak-ash1/hs754.ash1/164532_492888769329_509954329_5913592_5303267_n.jp g
must grow up!

Now I need to get some coilies ordered up for the back and sort out my tubs and turrets along with the boot floor... a weeks worth of thinking. Sadly im back to work now, so may have a small update on sunday!

Cheers,

Al

[HARBER07]

Very Shonky!

[alexcrosse]

only the paint ;)

[MarkLD]

Nice work, it really is a horrible area to work on. Keep at it.

[alexcrosse]

cheers mark, more enjoyable work from now on, changes from the original shell are involved with all other bodywork (more dramatic that loosing one little seam). Tubs and turrets will be a learning curve I'm sure! lol

Cheers,

Al

[alexcrosse]

Oioiiii, right. Had a good day at the unit today, got quite a bit done! First of all Kel got his A series out of his mini because after exiting a junction enthusiastically the diff locked, then when pulling into the garage it lost drive! So... spot whats wrong:
http://sphotos.ak.fbcdn.net/hphotos-ak-ash1/hs799.ash1/168945_10150090257944330_509954329_6055996_1922811 _n.jpg

Right, back to the propper car... todays job was tubbing the mini an getting rid of some rust. Sadly there was a fair amount of rust around the washer bottle mount, so that all had to come out, but first of all I marked where to cut with my 'tub-o-matic'
http://sphotos.ak.fbcdn.net/hphotos-ak-snc4/hs1380.snc4/163201_10150090258264330_509954329_6056007_6583339 _n.jpg

I marked up, then marked 10mm from the line and made my cut, after doing that, swore at the car for 4 hours and cut out ALOT of rust going right up to the rear panel, then once the rot was out set to work at flareing the arch, started with some mole grips slowwwwly then even more slowly went around with a hammer and dolly, being careful to hit the metal to stretch it rather than trying to bend it up.

http://sphotos.ak.fbcdn.net/hphotos-ak-snc4/hs1371.snc4/164357_10150090258114330_509954329_6056002_5031270 _n.jpg
I must say... im very very pleased with the result, i was worried it would warp to hell, but its exactly where it was as standard, and gives me a nice strong lip to weld to rather than a T weld which would have cracked with any abuse!

http://sphotos.ak.fbcdn.net/hphotos-ak-snc6/hs279.snc6/180700_10150090258169330_509954329_6056003_7961098 _n.jpg
:D

http://sphotos.ak.fbcdn.net/hphotos-ak-ash1/hs752.ash1/164371_10150090258209330_509954329_6056005_2798466 _n.jpg
Very happy, but as you can see on the pic above there was rust under the light, so that had to be cut out and a plate welded in

http://sphotos.ak.fbcdn.net/hphotos-ak-snc6/hs077.snc6/168726_10150090258354330_509954329_6056010_2179380 _n.jpg
Back to standard which is nice, I am going to make the lip separately as beating a single panel to that shape would have been impossible for me!

http://sphotos.ak.fbcdn.net/hphotos-ak-snc6/hs049.snc6/167924_10150090258304330_509954329_6056008_5056886 _n.jpg
Tub-o-matics are avaliable from £59.99, the Pro model (branded) is £89.99, kits dont include pen, or hole. lol...

Hopefully finish the plating and tubbing tomorrow :)

[Marcus Nordblom]

That lip looks perfect:)

[alexcrosse]

haha, cheers pal, funnily enough it wasnt... too high, lol. Reformed it higher though...


Got the flangey lippy bit on the repair that I did under the light, pretty pleased, looks standard and nice and flat now :D Now with higher reformed lip too, got away with it and no warpage
http://sphotos.ak.fbcdn.net/hphotos-ak-ash1/hs897.ash1/180560_10150092436789330_509954329_6084580_1861755 _n.jpg

Also had to replace quite a large section of floor where the washer bottle used to be, not all bad, got to make it nice and flat for sprintey aeroness :D
http://sphotos.ak.fbcdn.net/hphotos-ak-snc6/hs043.snc6/167327_10150092436659330_509954329_6084577_8221193 _n.jpg

Plate will go in to finish that side off on friday :) woop

[Burnard]

You planning on a flat boot floor for your new fuel tank?

[alexcrosse]

itll be as low as I can get it after the diffuser and exhaust, keep the weight as low as possible

[Burnard]

Sounds good. Cant wait to see this finished now. Sticking with the blue and 850badge yer?

[alexcrosse]

yer course mate! lol

[Burnard]

get roofless to make you a lil 'x2' sticker haha

[alexcrosse]

lol, nah 850 is the future, although I think the rest of the bodywork could hint a little at it not being one... lol

[Burnard]

how about 'historic racing club', 'Historic sprint series' or something along those lines, could make it more believable, complying to rules and regs etc... :lol:

[alexcrosse]

16v sprint championship! road legal though, incase the class ever gets divided... might stand a chance that way!

[MarkGTT]

Looking good, coming on nicely.

Like the idea of a 'road legal 16v sprint championship' I could be tempted :)

[alexcrosse]

do it mate :) the 16v sprint championship is what sold me on the vaux engine, cant wait to get involved

[Burnard]

but the v-tec has 16valves...

Wonder if you could be competitive with a road legal car...

[alexcrosse]

mine was quicker than vtec road cars on the previous spec at pod ;) and this will be a road legal car... not a daily driver!

[MarkGTT]

When mines up and running I will pop over and we can have a chat about it.

[Hayling mini]

Hi Alex
That is looking really good, the Southern Sprint team is looking more interesting every day:)

Regards

Jerry

[monkey]

mine was quicker than vtec road cars on the previous spec at pod ;)

No, don't say that :twisted:

[Hayling mini]

No, don't say that :twisted:

But the Vauxhall was slower than the 1.3 Suzuki;)

[Burnard]

No, don't say that :twisted:

Its true, and defiantly more drivable... :p

That 1.3 has a turbo and 4WD doesn't it? and one epic number plate which has to be worth about 100BHP

[alexcrosse]

1.3 suzuki with alot of fake displacement though jerry ;)

and monkey... bad luck, lol

[alexcrosse]

Ok... bit of a change of plan with the tubs... again! In my thinking, if i want to be competitive one of the most important things is attaching the car to the floor, to do this I am going to be running nice tyres, and to do this I need alot more room in the arch that previously anticipated, so... im having to move the entire tubs up, and space them out a little too.

http://sphotos.ak.fbcdn.net/hphotos-ak-snc6/hs264.snc6/179283_10150093474399330_509954329_6095986_4363045 _n.jpg

added 3" to the bottom of the inner arch so far
http://sphotos.ak.fbcdn.net/hphotos-ak-ash1/hs773.ash1/166310_10150093474564330_509954329_6095988_6764781 _n.jpg

This is where the new cut will be once I have finished fabricating the inners, could only do a half day today sadly!
http://a4.sphotos.ak.fbcdn.net/hphotos-ak-snc6/hs054.snc6/168453_10150093474774330_509954329_6095989_439209_ n.jpg

Thanks to Andy_S for answering all my annoying questions, lol.

More to come tomorrow afternoon, I hope to finish the tub, and get it positioned. Should give me an outer arch 6.5" higher than standard, meaning I can get miglia ride height with 13's and big tyres.

Also ordered my wheels today, should arrive in a coupla-few weeks I hope... VERY excited :D

Cheers,

Al

[MarkGTT]

interested to see what this will turn out like - what rims did you opt for?

[alexcrosse]

8x13's, should be nice! Wide enough for the rubber in mind!

[Burnard]

"no fat chicks"

[alexcrosse]

Ah ball sack. Decided against trailing arm suspension last night after a few ciders, reason being positive camber on the loaded wheel with corner induced body roll.

So... the back end is on hold while I do calculations to work out what will be best, and while I think about it I'm getting on with the roll cage to get some strength in the shell.

[Kam]

http://photos-h.ak.fbcdn.net/hphotos-ak-snc3/hs200.snc3/20760_224371114329_509954329_3051751_1367270_n.jpg

Alex - do you know the width of this diahatsu alternator? Are they the same as the suzuki swift ones - 110mm, hopefully its shorter.....

Cheers :D

[alexcrosse]

all the same I believe, the only difference in these nippon denso units is the orientation of the lugs and the type of plug

[Kam]

booger! :(

Thanks for the info and keep up the good work :cool:

[alexcrosse]

right... the plan for the back end has changed again... completely. Ive just decided to do as low as I can within MSA... which is very low, not the best for road use, but that isnt the point! So while I get the CAD design sorted for the back end I thought I'd crack on with the front section of the cage and the middle part of the shell!

last weekend I started with the main hoop... after laughing at my mates rebuild their A series engines side by side
http://a6.sphotos.ak.fbcdn.net/hphotos-ak-snc6/hs279.snc6/180707_10150098482474330_509954329_6165541_3710504 _n.jpg

I got the main hoop chamfered OK at the bottom and one of the side bars mocked up in place
http://a3.sphotos.ak.fbcdn.net/hphotos-ak-ash1/hs800.ash1/169090_10150098482569330_509954329_6165544_6668061 _n.jpg

side ones will be the toughest of the entire car I wreckon, joints to a mandrel bend and to the chamfered floor too... right arsehole.
http://a1.sphotos.ak.fbcdn.net/hphotos-ak-ash1/hs776.ash1/166637_10150098482644330_509954329_6165547_7011758 _n.jpg

mocked up both sides before getting everything back out again!
http://a3.sphotos.ak.fbcdn.net/hphotos-ak-ash1/hs901.ash1/180993_10150098482734330_509954329_6165550_3533652 _n.jpg

another before they came out...
http://a4.sphotos.ak.fbcdn.net/hphotos-ak-snc6/hs278.snc6/180684_10150098071704330_509954329_6157765_2710089 _n.jpg

two other mates fixing their A series engines... lol
http://a4.sphotos.ak.fbcdn.net/hphotos-ak-snc6/hs246.snc6/179482_10150098482819330_509954329_6165554_4381028 _n.jpg

had to repair the corner... cant really see where I did it im afraid, done back to standard. Then a 50mm hole drilled for the cage to drop through later!
http://a2.sphotos.ak.fbcdn.net/hphotos-ak-snc6/hs275.snc6/180349_10150098482904330_509954329_6165557_978891_ n.jpg

same the other side too...
http://a6.sphotos.ak.fbcdn.net/hphotos-ak-ash1/hs895.ash1/180326_10150098482999330_509954329_6165562_7375526 _n.jpg

got the cage back in, quickly tacked the roll hoop and side bars. Then got the dash and roof bar in :) Pretty please with how its all fitting. Just taking plenty of time to make sure its all straight an correct to the blue book / roll centre certification.
http://a1.sphotos.ak.fbcdn.net/hphotos-ak-snc6/hs308.snc6/181682_10150098483074330_509954329_6165564_4131855 _n.jpg

anothe pic...
http://a1.sphotos.ak.fbcdn.net/hphotos-ak-snc6/hs278.snc6/180632_10150098483234330_509954329_6165570_3781841 _n.jpg

[miron]

Looks rubbish Alex!

i wasnt fixing the engine.....i was just waiting for it to break again!

[alexcrosse]

54 days... 54 miles, lol!

[alexcrosse]

Didnt manage to get down the unit on Saturday, was a bit worse for wear after Friday, but got some bits done today, inbetween drinking coffee and eating loads of biscuits, it was bourbon and shortcakes on the menu today, very nice.

Anyway, less about biscuits more about mini (although they were very nice biscuits). Got the roof bars chopped to size and then tacked them in place like so,
http://a6.sphotos.ak.fbcdn.net/hphotos-ak-snc6/182815_10150102184089330_509954329_6216929_600196_ n.jpg

Then moved those plates out the way and dropped the cage through, found it was best to drop only the back as it drew the front away from the A pillers for more welding room. Once dropped down did all the welding on top of the cage.
http://a7.sphotos.ak.fbcdn.net/hphotos-ak-ash1/179823_10150102184194330_509954329_6216931_409830_ n.jpg

And again... although, looking at this it appears I got my lefts and rights confused, ah well, no harm done!
http://a5.sphotos.ak.fbcdn.net/hphotos-ak-ash1/180739_10150102184254330_509954329_6216932_890446_ n.jpg

Thought id cut out all the headlining mounting stuff, atleast 3 grams saved here... but saved myself the bother of annoying people saying "why didnt you cut them out" which was my main reason for doing it to be honest!
http://a2.sphotos.ak.fbcdn.net/hphotos-ak-snc6/168955_10150102184314330_509954329_6216934_7720451 _n.jpg

does make the roof line a little neater though... not that ill see it behind the cage, lol.
http://a8.sphotos.ak.fbcdn.net/hphotos-ak-ash1/182283_10150102184434330_509954329_6216935_7406962 _n.jpg

needed to rebend all the plates , I expect its differences between minis rather than rollcentres bending effort though. Once done, cleaned them all up, put weld through primer on the sealed side, welded, and sprayed. Lovely chuffing great 3mm plate with some man-welding.
http://a4.sphotos.ak.fbcdn.net/hphotos-ak-ash1/180659_10150102184499330_509954329_6216937_7538223 _n.jpg

Roof bars in, inaccessable welding done, now can get on with door bars, sill bars, and all the bars to the back. Happy days.
http://a5.sphotos.ak.fbcdn.net/hphotos-ak-ash1/181715_10150102184604330_509954329_6216939_6270869 _n.jpg

Cheers!

Al

[alexcrosse]

will be going for a bit of a drive at the weekend to pick up a new present for the car ;)

[Hayling mini]

Looks good Alex, are you coming to Barkston in June?

[alexcrosse]

I wish, doubt itll be done by then to be honest, still got the rear suspension to do, and I need to either alter or make a new front subframe too. Then all new loom, instrumentation, calibration, painting and finally a new heart!

[Hayling mini]

I wish, doubt itll be done by then to be honest, still got the rear suspension to do, and I need to either alter or make a new front subframe too. Then all new loom, instrumentation, calibration, painting and finally a new heart!

Plus a new wallet by the sound of it, what is your target date to finish?

[alexcrosse]

wallets just lightweight now, race spec! November 2052... no idea, want to be doing a ring and spa trip with a few opel mates in September, O'rouge is beckoning!

[Marcus Nordblom]

top work with the cage:)

White mini in the background, is it running mercedes lights?

[alexcrosse]

cheers mate, yer it is, and grill... and badge! LOL! never seen a mini overheat as much as he managed, burnt the paint on the rocker cover and turned a red block into a black one, very very impressive!

[Kam]

want to be doing a ring and spa trip with a few opel mates in September, O'rouge is beckoning!

September eh? As you know theres 'another' run in september so I might see you out there :cool:

[alexcrosse]

lol, we'll have to plan around you lot then, wouldnt want to over crowd the place =p

[Kam]

:lol: We'll be there 31/8 till 7/9, retro cars only, hopefully matt will take his C16XE mini this time........

[alexcrosse]

Youll have to do something to your vtec to keep up with a vauxhall mate!

[Kam]

Don't worry mate I'll think of something, even if its sabotage in the middle of the night at the campsite when everyones asleep......:p

Let us know when you got a date and are heading out there, ours is being booked up so our date is now set in stone

[alexcrosse]

i will, itll be muchhhh nearer the time, if the cars done ofcourse.

*NEWS FLASH* new engine is to be picked up tomorrow!!!

[MarkGTT]

spec?

[alexcrosse]

only mild cams and jenveys when I've rebuilt it

[Kam]

What happens about your roll cage as you've made it yourself? Don't they need to be MSA approved or something?

Sorry I don't know squat about this but I presumed cages were certified or something?

[alexcrosse]

its a roll centre cage, some parts dont conform with the standard MSA regs, but Roll Centre had the actual design certificated through the MSA & MIRA etc so I can get my logbook fine. Originally it was a cage designed for baldwin and his miglia, he won the 2000, 2001, 2003, 2004 and 2005 championship with it, seemed good enough for me!

[NudgerSS]

So is this going to be Tink V6 then seeing as you need to do a new front subframe?

[alexcrosse]

Right... getting annoyed now... this is the third time ive typed this out, computers crashed twice!

john - it is version 6, but shouldnt require a new subframe, will be modified so I can get the shell as low as I need it though :)

Right, picked this up to cheer myself up a tad, feeling properly ill!
http://a1.sphotos.ak.fbcdn.net/hphotos-ak-snc6/184950_10150106202794330_509954329_6260947_1638134 _n.jpg

Got the drop points sorted and the car leveled out, trimmed the cage legs to suit, then got the sill bars cut... number 1 -
http://a7.sphotos.ak.fbcdn.net/hphotos-ak-snc6/185906_10150106202909330_509954329_6260952_404866_ n.jpg

and number 2
http://a8.sphotos.ak.fbcdn.net/hphotos-ak-snc6/185790_10150106202854330_509954329_6260949_2584560 _n.jpg

Then started cutting the cross member out, dont need it with all this cage-ness
http://a4.sphotos.ak.fbcdn.net/hphotos-ak-snc6/183542_10150106203019330_509954329_6260954_4655264 _n.jpg

Got the engine a bit more stripped, wont be doing much more work on this til the shells done, may just check the cranks OK and thatll do.
http://a1.sphotos.ak.fbcdn.net/hphotos-ak-snc6/180646_10150106202494330_509954329_6260939_8336723 _n.jpg

Also got the hoop brace in, which is good and fits well. Just need to Finish cutting the cross member tomorrow, then double check drop points, then weld the cage to the floor and level the dash bar which needs correcting a few mm.

Need some sleep soon... feel very ill!!!

Cheers,

Alex

[HARBER07]

x2 on the ill bit mate. Felt like crap the last week. Looking good anyways!

[alexcrosse]

Starting to fell a tiny bit better :( had a lye in til 8.30 (luxury) and chilled drive to the unit, got a massive spirit level... so on with the day!

First off all got my mahoosive spirit level and made 4 raised datum points on the floor all perfectly level with eachother so I could ensure there was no twist in the shell... veryyy interesting photo:
http://a7.sphotos.ak.fbcdn.net/hphotos-ak-snc6/180932_10150106947659330_509954329_6269752_5461218 _n.jpg

can see 2 of the datums here taped to the floor
http://a1.sphotos.ak.fbcdn.net/hphotos-ak-snc6/183867_10150106947729330_509954329_6269753_1818367 _n.jpg

Once levelled I welded the cage to the floor, and all sorted! Then got the right level for the sill bars, corrected the dash bar, levelled the hoop brace, and half welded it all in. Then set to work removing the rest of the cross member and gearbox selector bracket thing
http://a3.sphotos.ak.fbcdn.net/hphotos-ak-snc6/180138_10150106947149330_509954329_6269744_2975660 _n.jpg

Nice crossmember-less floor :)
http://a2.sphotos.ak.fbcdn.net/hphotos-ak-ash1/181640_10150106947399330_509954329_6269748_2849657 _n.jpg

Then put my coffee mug down and came home!
http://a1.sphotos.ak.fbcdn.net/hphotos-ak-snc6/182067_10150106948099330_509954329_6269758_201603_ n.jpg

Job done, next time... door bars and stuff, but race retro next weekend :)

Cheers,

Alex

[alexcrosse]

http://a4.sphotos.ak.fbcdn.net/hphotos-ak-snc6/182020_10150108846229330_509954329_6288377_2715170 _n.jpg

MASSIVE BOX :D been buying presents for myself again, February's present is....

...ill tell people on Saturday when I'm back in the UK to open it ;)

[MINI_BIG_AL]

im betting its a seat!!!! lol

[alexcrosse]

Nope, already have my two motordrive FG seats :)

[MINI_BIG_AL]

hmmmmm puzzling!

[1WHEELKING]

racing dash.....

Nathan

[Birdman]

Set of alloys or maybe the diffuser you mentioned earlier?

[monkey]

A Thai mail order bride? :p

[1WHEELKING]

A Thai mail order bride? :p

pmsl!!!^^^

[alexcrosse]

A Thai mail order bride? :p

yep, buy two get the third free, hence the size of the box, feel slightly bad about leaving them in there until im back on Saturday, im sure theyll be fine... :beer:

and no racing dash! a true racing dash is no dash!

[MINIMAD30]

Set of wheels without tyres?

[Hayling mini]

Set of wheels without tyres?

That would be my guess too, 13" x 7"?

[alexcrosse]

13" x 7"?

nope, lol

[MINIMAD30]

Really big nitrous bottle??

[Hayling mini]

13"x8":)

[alexcrosse]

Really big nitrous bottle??

LOL! that would last a while huh!

[MINIMAD30]

Hmm, any chance of it being something small in a huge box? Or does is it something that fills the box?

[alexcrosse]

Im surprised you havn't noted my bliss ignorance to Jerry's accuracy, lol.

[alexcrosse]

http://a1.sphotos.ak.fbcdn.net/hphotos-ak-ash4/185830_10150110970824330_509954329_6308820_1470296 _n.jpg

box open! 13x8 force racing split rims, ubeerrrrr light!

http://a2.sphotos.ak.fbcdn.net/hphotos-ak-snc6/185641_10150110769519330_509954329_6306371_3604806 _n.jpg

http://a7.sphotos.ak.fbcdn.net/hphotos-ak-ash4/183019_10150110971019330_509954329_6308821_3644529 _n.jpg

now off to race retro for me :D

[Burnard]

http://www.youtube.com/watch?v=VLnWf1sQkjY