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Old 4th August 2015, 04:45 PM   #621 (permalink)
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You could have drilled and tapped the cast boss on the compressor housing mate to save welding to it. That's what it's there for unless it's in a position not suitable for you?

Nice purchase on the plane do you have a license to fly it?
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Old 4th August 2015, 06:18 PM   #622 (permalink)
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You could have drilled and tapped the cast boss on the compressor housing mate to save welding to it. That's what it's there for unless it's in a position not suitable for you?
That would have been my first choice. Unfortunately the turbo has had a shaft speed sensor at some point (which I plan to add soon myself) which is very close to the cast boss. I think there would definitely have been some interference hence the reason for relocating the take-off somewhere out of the way...

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Nice purchase on the plane do you have a license to fly it?
Yes. Had a PPL for MANY years and a plane was always on the cards. Looking to get an IR at some point and will get something a bit more tasty when the time is right . Thinking C182T/C210 or maybe even a little C340 if I can stop going daft on other projects!!!!



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Old 4th August 2015, 06:52 PM   #623 (permalink)
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Yh I did see your shaft speed conversion but didn't look to close in pics, obv now you'll have to have your compressor exit pointing towards the ground instead of pointing the wing as it will hit bonnet?


I no nothing about planes mate so that doesn't mean a lot to me, do they cost a lot to maintain and use?
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Old 5th August 2015, 09:23 PM   #624 (permalink)
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Yh I did see your shaft speed conversion but didn't look to close in pics, obv now you'll have to have your compressor exit pointing towards the ground instead of pointing the wing as it will hit bonnet?
It's not as vertical as it looks in the pic TBH, plus I'll be using a 90deg fitting. I'll have no worries with bonnet clearance.....!!

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I no nothing about planes mate so that doesn't mean a lot to me, do they cost a lot to maintain and use?
Depends on many factors just like cars. I'll be paying £100/month for fixed costs (hanger, landing card etc) and the group charges itself £85/flying hour which goes into a pot for things like maintenance, upgrades etc. A modest first step onto the aircraft owning ladder


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Old 19th August 2015, 03:45 PM   #625 (permalink)
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SO, despite the 'setback', I've not been idle......

Made up a couple of fibreglass indicator blanks over the last few days.....





They're not perfect but I'm very happy with how they've turned out. The mould I made is in good shape so might run off a couple in carbon at a later date as I used the last of the carbon experimenting .


Have also decided (pretty much) to use the intervening period to do some 'stuff'

1. Have my spare Aragosta dampers rebuilt and fitted.
2. Pull engine and fit OS R4C quad plate clutch
3. Fit replacement front sump with 4.3 CWP
4. Fit rear Nismo 2-way LSD with 4.3 CWP
5. Fit my Greddy 9.7mm cams


I MAY even, depending on my feeling at the time, get some forged rods and 87mm pistons and chuck them in.... Would seem like a sensible time to do it.



So, still stuff happening!!



TT
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Old 20th August 2015, 10:02 AM   #626 (permalink)
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As invariably happens, I was sat the other day with money burning a hole in my pocket so ended up buying a pair of Bi-xenon lights....



Will remove std headlights and make up some carbon or GRP blanks. The near-side one will have a duct incorporated which will provide air to the monster K&N and both will have one of these lights embedded. Had thought about doing this for a while now so pushed the 'buy' button and stopped procrastinating....


TT
I have my old headlights in the back of the garage. They have a similar kit fitted (though knackered and LHD). If you want to have them to use as bases for you new kit you are welcome. Then you could keep/sell you OEM lights without having to chop them up.

Shout if that's any use for you.
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Old 20th August 2015, 10:33 AM   #627 (permalink)
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I have my old headlights in the back of the garage. They have a similar kit fitted (though knackered and LHD). If you want to have them to use as bases for you new kit you are welcome. Then you could keep/sell you OEM lights without having to chop them up.

Shout if that's any use for you.
Thanks Cris.
I'm going to make FRP/CFRP copies of the OEM lights and modify them to take a light each and a scoop on the N/S. Should be fun!

Thanks for the offer anyway


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Old 20th August 2015, 10:42 AM   #628 (permalink)
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Thanks Cris.
I'm going to make FRP/CFRP copies of the OEM lights and modify them to take a light each and a scoop on the N/S. Should be fun!

Thanks for the offer anyway


TT
Fair enough I was thinking you might like to use the rear plastic housings of the headlights and replace the glass with GRP/carbon. That way you'd retain the OEM headlight adjustment which might save some headaches.

Now I'm thinking that might not work with the scoop you've mentioned - the hole in the front 'bulkhead' is on the outside I think which is where the OEM dipped beam sits.

Good luck with it anyway!
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Old 8th September 2015, 03:04 PM   #629 (permalink)
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Gave the 306 a wash and wax today and while in the garage putting cleaning stuff away decided to have a look at my xenon kit. Next thing I know I'm drilling stuff!!!

Mounted ballast on O/S..



And some other box...



Near side was slightly different due to the fact that it has a cut out compared to no cut out on off-side. Had to be a bit creative!



Have run out of various composite supplies so once they arrive I'll make a start to designing some light blanks/xenon holders....



TT
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Old 13th September 2015, 08:15 PM   #630 (permalink)
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Well, manifold's arrived at FedEx Stansted!! Should be here Tues..


V excited!!!


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Old 23rd September 2015, 09:44 AM   #631 (permalink)
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Well, after a bit of tooing and froing with FedEx(!!!!) I finally have my manifold. Behold!!!!......








The pics really don't do it justice....a very overused term but 100% correct in this case. The manifold is, shall we say, rather robust and weighs a ton!! Not cheap, but (and I'm not even wincing when I say it!) worth the money!.. As you can see I went for the 2000deg ceramic coating which is rather nice and when wrapped with DEI wrap should give extra thermal protection under bonnet!

As I've decided to pull the engine over the winter and fit forged pistons/rods the manifold will stay in its box only to be trial fitted so I can get the correct lengths sorted out for oil/water pipes.


On another subject, due to the fact that I have removed and blanked the indicators I decided to get some LED replacements. Initially I wanted clear lenses with amber LED's but trying to find them in the right shape was proving rather difficult. In the end I settled for an amber lensed indicator in the rectangular shape I wanted.....



You can see them just below the Motul stickers. And when on.....



Are actually rather bright! V pleased with the way they have turned out!

Have made up some moulds from the main headlamps so will be getting cracked on with making up some GRP shells to house my Xenon lamps and scoop.




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Old 23rd September 2015, 10:14 AM   #632 (permalink)
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Not made from copper I hope?
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Old 23rd September 2015, 10:18 AM   #633 (permalink)
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Not made from copper I hope?
No... Personally I agree with your argument (re thermal efficiency) that you posted up about using copper piping!!

I hear that copper's dropping in price so time might be right to get yourself some more



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Old 23rd September 2015, 11:57 AM   #634 (permalink)
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No... Personally I agree with your argument (re thermal efficiency) that you posted up about using copper piping!!

I hear that copper's dropping in price so time might be right to get yourself some more



TT
Aye, thats the difference between common practice and common sense.
Your project is coming on well. Any idea when it might move under its own power?
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Old 23rd September 2015, 02:30 PM   #635 (permalink)
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No!!!




At this rate, I'll be too old to drive it when it's ready...




Realistically, hoping to be done around this time next year as I've a few other things needing my cash and attention.....


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Old 29th September 2015, 06:30 PM   #636 (permalink)
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OK, update...!


Take an Absolute vodka bottle and cover it in gelcoat!..



Then add a few layers of fibreglass tissue, chopped strand matt and some coremat and you have this....



Then, make some moulds of your headlights..



After a bit of fettling you get this...



Which after a bit of cutting out of the hole looks like this...



After I'd extracted one of the xenons from the box it kind of looks like this...





And with a bit of power to the halo looks like this... (Even THATS bright!!)



And lastly, jury-rigged on the car to give an idea....



OK, so there's a good bit of finishing work needed but you get the idea! Very happy with that TBH. Turned out better than I'd hoped as this is only attempt no.1..!!!! I really expected to go through a few iterations before having something useful so this is a big bonus!!
The other side will be the same but I'll utilise a Revotec duct and incorporate it into the final product to give some air to the (huge) K&N which will sit directly behind.





Also, temptation got the better of me and I thought I'd get the manifold out for a trial fit.....





I'm over the moon with it but looking at the front wastegate, I've no idea how I'm going to get a dump pipe to join to the downpipe . However, I'm not too concerned about that right now....that'll be the exhaust fabricators problem... Rear one'll be easy though!!


Moved the boost solenoid to a better location and used some hardline for the boost feed...







Don't worry though, I'm using solid engine mounts so there will be NO movement between engine/chassis just in case some of you were having palpitations!!


And lastly, got some Ring foglamps and fitted them a'la stock-rods from the 80's/90's . Love the look..




So, will have to wait until I get another Absolute vodka bottle as I had to destroy the last one to get the light holder free!!..... Never mind!!! . Will now get on with sizing the correct length lines and fittings for all the water/oil/air pipes for turbo install.



TT
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Old 29th September 2015, 06:59 PM   #637 (permalink)
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That's the dedication I love - having to drink a bottle of vodka

Love your work - very inspiring for your own take.
On a side note - how tight is tight on the tubby-turret?
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Old 29th September 2015, 07:26 PM   #638 (permalink)
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That's the dedication I love - having to drink a bottle of vodka
I'm not a big fan of vodka TBH. Bottle wasn't mine

Quote:
Love your work - very inspiring for your own take.
On a side note - how tight is tight on the tubby-turret?
Thanks!!

Turbo has a decent amount of room against the turret to be fair. Have a DEI turbine blanket as well as some gold reflector to add to turret so heat won't be a problem. Also going to lag the manifold prior to fitting!!


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Old 8th October 2015, 10:18 PM   #639 (permalink)
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So, after a few days of work I managed to do a couple of bits and bobs....

Finished O/S blank/light.




Pretty pleased with that !!!!

Got on with the bigger challenge of getting the N/S one done...

Did the same thing as the O/S and made a 'cup' to hold the light which was easy enough and married that up to the headlight blank. Bought a scoop but rather than use it, decided to take a mould off it and incorporate a box-like section underneath which would allow me to cut at an angle to get the best fit to airflow. At least now I can run off as many scoops as I'm ever going to need ....



Reinforced the join with plenty of F/G and it was set perfectly!!...


OK, the 'bridge' bit was just a bit of CSM I slapped on as I had a bit of resin left. Serves no real purpose

Once it was set I then started cutting out the front aperture....





You can see the usefulness of having a boxed bit as it allowed me to orient the scoop straight at the airflow without cutting the scoop itself.

And one at a slightly more advanced stage...



Again, needs a bit of finishing and painting but you get the idea. All-in-all I'm VERY pleased with the way they have both turned out. The weight saving is phenomenal and the scoop should feed my humongous K&N with lots of nice cold air!!
The lights are pretty superfluous for a track car but then, you never know when you might need some light!!

Will hopefully finish this whole thing tomorrow as I'm fed up of having F/G dust all over me! Thankfully I have a full-face 3M mask...


Which keeps the nasty stuff out of the lungs but even so, it gets bleedin EVERYWHERE!!!


Next thing will be to work out a way to secure front grille now that the little lugs on the headlights are not there any more..


TT
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Old 19th October 2015, 02:39 PM   #640 (permalink)
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So, after plenty of painting, dressing and fabrication my headlight replacement project is finally complete!!! I have to say that it has turned out exactly as I had envisioned it and had taken far fewer attempts to get a final version than planned. Overall, I'm very pleased..... behold....










All-in-all, the lights were about £90, the fibreglass and supplies were probably about £25 (it was materials that I had lying around anyway) and my time was free.

Feels rather satisfying to have put a variety of skills to use in this little project and come up with something useable and reasonably decent . My 'garage battery' that I use as a test power source was flat which meant that I couldn't test the whole system. I will do this over the next couple of days but I'm confident it'll all work as each component was tested individually and was fine.


Right....... onto the next job...







TT
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