Thread: Stirlsilver's Disco Ute Project

Late night shenanigans - the design of the manifold & turbo flanges are done. Time to send them to the laser cutter!

Checking in to report on progress this week.
I've settled on the design of the turbo dump pipes. I have a problem on the right hand side where the tightest butt weld elbow available doesn't have a small enough radius and as a result it is going to foul on the compressor. I'll deal with that when it comes to building the pipe:




The tray frame was bolted on again in preparation to attach the lockers:


The lockers leveled and in the process of being bonded together:


The cam position sensor was fitted, here it is with the cap to hold the shaft in position during installation:


Here is a short video showing the testing, initially the cam position sensor signal dropped out at low RPMs so some tweaking of the gain and hysteresis was required in the ECU. The signal is now solid. Quite happy it all works well:
Rover V8 on test rig - testing the cam position sensor - YouTube

After the lockers cured, I prepped the aluminium for bonding to the steel frame:




Bonding to the frame:




I made a start on the LPG nozzles. While I could have gone with drilling and tapping the inlet manifold injector ports and then drilling and tapping again to install the nozzles. I decided that I would just cut up the old injectors and thread lock the LPG nozzles into the nozzles of the injectors. While the holes were too big to tap a thread they were the exact size of the LPG nozzles so the thread locker should work perfectly here:




The injector module was wired onto the ECU and the injectors tested. All working perfectly (the number of wires is exploding!). I started the engine and the injectors were opening & closing sitting on the bench. Also all the LPG system sensors are wired up and giving readings:

I just got word from ARE that my intercooler cores are ready and will be shipped out shortly

This build just gets more and more EPIC.

Well done. A great read.

Ian.

Originally Posted by mrapocalypse

This build just gets more and more EPIC.

Well done. A great read.

Ian.

Thanks Ian! I don't quite know what else to say!

It's time for the usual progress update. Looking back I don't think I got as much done as usual, but I guess that happens from time to time.

After going around and pouring in two full tubes of Sikaflex to glue and seal all the joints which connect the floor of the lockers to the tray frame I used my trick of using the two part polyurethane foam to bond the areas between the lockers and tray frame with large gaps. The end result was there were no gaps where water could seep into and cause corrosion.







I then moved on to fitting the tail lights. Using CAD I used the information from the LED light supplier for the cutout and simply made a template which I traced over.







Anyone with a sharp eye might notice that my die grinding skills need some work. I had the die grinder run away on me 3 times gouging the external surface of the aluminium. I was really annoyed at myself that it happened. Nothing I can really do...

To finish, I used a coat of seam sealer over the foam to seal it all up. It's not pretty, but it won't be visible when then tray is finished and it gives that extra barrier to water ingress.

The intercooler cores are in my hands. They are certainly solid!


I've also made a start on the plenum assembly. This is the line I'm thinking along at this stage.

I take it you do have a plenum that you will feed the outlet of the coolers into.

Sounds wicked mate!! i have seen one in Canada when i was working there. Man did it look TUFF old mate filled it with up LS1 chevy. big wheels big lift and all the toys custom steel tray with the timber deck boards. it really stood out against the big chev, ford, dodge, trucks that the north americans love. would love one myself. hope it goes well mate!!!