Stirlsilver's Disco Ute Project

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Originally Posted by Scouse

Whereabouts in Wollongong is it?
It's school holidays ATM & we're often down at Bulli Beach on warm afternoons so I can pick it up if it's not too far from there then drop it off next week.

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Hi Scott,
It's a very nice offer! But I'm not sure if you know what you are getting yourself into there:
https://www.aulro.com/afvb/images/im...15/01/1300.jpg

The engine is in Unanderra in a garage of a plumber there. I used their forklift last time (actually the guys used their own as I don't have the license) to get it out of the container and into their garage. Because the engine and test bed is 1.8m wide from what I could find, it won't fit in a box trailer so it would need a car trailer to transport it.

It's not exactly a simple thing to move it. Still offering??

It might be a bit of a squeeze for a 7x4 trailer.

I guess that easy transport was not one of the engine stand design criteria. :)

May fit in/on my buggy trailer... it's about 10x5'

Would just need a way to load/unload it, I am in Wollongong way too often for uni anyway :p (even in the holidays, to play race cars).

Cheers
Will.

Quote:

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Originally Posted by slug_burner

I guess that easy transport was not one of the engine stand design criteria. :)

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It's on wheels so I guess I could just tow it 'as is'.


Just need to sort some lights out - safety first ;).

Quote:

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Originally Posted by Scouse

It's on wheels so I guess I could just tow it 'as is'.


Just need to sort some lights out - safety first ;).

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It still has the radius arm mounts... Just whack an axle under there and weld an A-frame to the other end. Instant trailer!

Quote:

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Originally Posted by DeeJay

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"Also, another question, what do people think the best method is of going about the project in relation to the engineer. Should I get him to come in before I start to do anything, to discuss what I intend to do and what they would be looking or should I build it, then show it to the engineer say half way through and then at the end?"

Stirl,
I got the engineer out for my project before I got really stuck into it. I'm not sure if I had to though, as he came out half way through it anyway and then I presented it to them at the finish. They charged me $125.00 for each visit & all I did at the start was outline what I wanted to do to him and he just nodded. I reckon if you can demonstrate that your project is fairly common then I would say just get him out halfway & actually get some value out of the visit because by then you may have some questions.

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Dee Jay, who was your engineer?
cheers Ian

At last, some real progress!! On Saturday I went to LVS and purchased an old cylinder head for $40 to use as a jig for the manifold. I've now finished the left hand side exhaust manifold. All that is left is a little bit of grinding.

The tricky splice of a 3rd elbow into the collector:
https://www.aulro.com/afvb/images/im...15/02/1080.jpg

Welding up the elbow for cylinder number 1:
https://www.aulro.com/afvb/images/im...15/02/1081.jpg

A little bit gappy, but nothing I couldn't patch up with the TIG:
https://www.aulro.com/afvb/images/im...15/02/1082.jpg

Another tricky splice, for cylinder number 3 into the number 1 runner. This one turned out much neater. A spacer was used on the cylinder number 1 flange to compensate for the deformation from all the welding I was about to do on one side of the pipe:
https://www.aulro.com/afvb/images/im...15/02/1083.jpg

https://www.aulro.com/afvb/images/im...15/02/1084.jpg

And the assembly all welded up. Still hot so waiting for it to cool:
https://www.aulro.com/afvb/images/im...15/02/1085.jpg

https://www.aulro.com/afvb/images/im...15/02/1086.jpg

Next up the right hand manifold!

The goal this weekend was to get the other manifold finished. Goal achieved :D:

First though, i did a trial fit of the LH manifold & turbo.
https://www.aulro.com/afvb/images/im...15/02/1087.jpg

https://www.aulro.com/afvb/images/im...15/02/1088.jpg

I dummied up the dump pipe. A tight squeeze but there is enough space to fit insulation between the pipe & firewall. I've also realized that the turbo needs to be fitted and removed with the dump pipe as there won't be access to some bolts. So time to go to an exhaust shop and buy some flanges.
https://www.aulro.com/afvb/images/im...15/02/1089.jpg

https://www.aulro.com/afvb/images/im...15/02/1090.jpg

Positioning of the RH turbo in the engine bay.
https://www.aulro.com/afvb/images/im...15/02/1091.jpg

https://www.aulro.com/afvb/images/im...15/02/1092.jpg

The first runner that matches up with the positioning of the turbo in the engine bay.
https://www.aulro.com/afvb/images/im...15/02/1093.jpg

And then the tedious process of splicing pipes and elbows together.
https://www.aulro.com/afvb/images/im...15/02/1094.jpg

https://www.aulro.com/afvb/images/im...15/02/1095.jpg

https://www.aulro.com/afvb/images/im...15/02/1096.jpg

Finished!!
https://www.aulro.com/afvb/images/im...15/02/1097.jpg

https://www.aulro.com/afvb/images/im...15/02/1098.jpg

I've been asking some questions on the MegaSquirt forum about how to change the code of the ECU so that the fuel pressure which is measured doesn't automatically get changed to a differential pressure by subtracting the rail pressure with the manifold air pressure.
Megasquirt Support Forum (MSEXTRA) • Fuel pressure compensation using absolute rail pressure only (View topic)

It looks like I need to do a little bit of hardcore coding of the ECU!

On a separate note, I should finally be picking up the engine this weekend and I'll be able to move on to seeing if I can get the LPG injectors to work!