Corvette powered Defender
This might sound obvious but I'd try to go as low as possible to keep below any heat source or wrap the pipe with exhaust wrap. It would be a shame to lose the cold dense air drawn in from the rear of the cab and as anyone who has driven a V8 series or defender knows the transmission tunel area can get rather hot.
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5/4 of people admit that they’re bad with fractions.
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davew
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I think wrapping it might be an idea although I don't expect the air to be hanging around very long to get warm 
Managed to get the rear section of the exhaust sorted today including cutting out the old hole in the rear cross member, taking it from just over 2 inch to 3 inch diameter. Welded the pipe together, just need to make a few mounting points now and it's done. Sounds sweet too.
Patrick bled the power steering, finally got rid of the rattling noise it was making !
Going to try and get the new radiator in tomorrow if it's ready, ideally we'll get the rad in, Mk 1 of the air intake (piped to the rear of the engine with the K&N filter stuck on the end) and get the bonnet on, then I can get the new front brake disks and pads fitted this weekend along with the bush kit and generally tidy it up. If all goes well I'll try and get it MOT'd on Monday so I can put some miles on it and get the tuning somewhere near.
Managed to get the rear section of the exhaust sorted today including cutting out the old hole in the rear cross member, taking it from just over 2 inch to 3 inch diameter. Welded the pipe together, just need to make a few mounting points now and it's done. Sounds sweet too.
Patrick bled the power steering, finally got rid of the rattling noise it was making !
Going to try and get the new radiator in tomorrow if it's ready, ideally we'll get the rad in, Mk 1 of the air intake (piped to the rear of the engine with the K&N filter stuck on the end) and get the bonnet on, then I can get the new front brake disks and pads fitted this weekend along with the bush kit and generally tidy it up. If all goes well I'll try and get it MOT'd on Monday so I can put some miles on it and get the tuning somewhere near.
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davew
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The new radiator arrived at last ! The oil cooler isn't ready yet but I went and got the radiator anyway. If it works half as well as it looks it should be just the thing...
Managed to get the rad fitted into position, still need to weld the bottom mounts though as they need removing and modifying slightly because the rad is too high at the moment.
Fitted the bonnet after stripping all the hardware from the old one, I'll need to fabricate some brackets to take the bonnet prop and, as it turns out, I now need to move the expansion bottle in an inch as it catches the side of the bonnet. Spent some time with a length of 4 inch aluminium pipe and an air filter and figured out where the air intake can be mounted.
Moved the transfer box lever back so the original gearbox tunnel can be used until I get a new one fabricated to take the snorkel.
I'll spend the weekend finishing various jobs off and tidying things up so it's ready for it's MOT. Hopefully the air inlet hoses will arrive on Monday and, if all goes smoothly I'll get it on the road for Tuesday.
Managed to get the rad fitted into position, still need to weld the bottom mounts though as they need removing and modifying slightly because the rad is too high at the moment.
Fitted the bonnet after stripping all the hardware from the old one, I'll need to fabricate some brackets to take the bonnet prop and, as it turns out, I now need to move the expansion bottle in an inch as it catches the side of the bonnet. Spent some time with a length of 4 inch aluminium pipe and an air filter and figured out where the air intake can be mounted.
Moved the transfer box lever back so the original gearbox tunnel can be used until I get a new one fabricated to take the snorkel.
I'll spend the weekend finishing various jobs off and tidying things up so it's ready for it's MOT. Hopefully the air inlet hoses will arrive on Monday and, if all goes smoothly I'll get it on the road for Tuesday.
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davew
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Spent today tidying things up, got the speedo cable in then spent a few hours trying to mount the transfer box lever, which turned out to be a real bitch of a job. Had to modify the gear lever bracket so the transfer box lever wouldn't foul on it.
Getting the tunnel back in with the gear lever bracket fitted was another trial by torture - just as well there was nobody around as the language at times was quite explicit. Eventually I managed to get it in and worked out a way of routing the gear select cable through the top of it without cutting any holes in it (no point in ruining it when I plan to change it soon anyway).
Got most of the wiring and pipework secured away from sources of harm, refitted the floor behind the seats and the rear winch cover. Should now be able to drive it without a force 10 gale blowing all the dust into the cab.
Bolted the roll cage together again where we'd had to remove some of it's bolts for access.
Still seems to be an awful lot of these little "tidying up" jobs left to do and they seem to take much longer than you would expect !
Getting the tunnel back in with the gear lever bracket fitted was another trial by torture - just as well there was nobody around as the language at times was quite explicit. Eventually I managed to get it in and worked out a way of routing the gear select cable through the top of it without cutting any holes in it (no point in ruining it when I plan to change it soon anyway).
Got most of the wiring and pipework secured away from sources of harm, refitted the floor behind the seats and the rear winch cover. Should now be able to drive it without a force 10 gale blowing all the dust into the cab.
Bolted the roll cage together again where we'd had to remove some of it's bolts for access.
Still seems to be an awful lot of these little "tidying up" jobs left to do and they seem to take much longer than you would expect !
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davew
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Finished off the radiator mounts first job, welding new lower mounts and modifying the upper mounts slightly to make sure the radiator is fully rubber mounted without touching the steel of the brackets.
The top hose that Patrick had cobbled together for the old radiator was fine with the new one, as were the 2 small circulation pipes to the manifold and the expansion tank. The bottom hose, on the other hand, turned out to be a nightmare due to the wierd angles involved and the lack of suitable hoses. Eventually I managed to get the right angle using 2 part hoses and an aluminium joining tube which was a bitch to fit but finally gave up in the end and joined up without any creases. Might buy a couple of Samco 45 degree bends and use a similar piece of pipe for the final version. For the moment though, it's water tight and it's full of coolant again.
Spent yet more time fixing cables securely out of the way, think all the under vehicle cables are now sorted, just the mass of cables behind the drivers seat to sort out now !
Pam was with me today so, once the rad was full of water, I fired it up so she could hear what it actually sounds like in the flesh rather than the narrow spectrum version on the video camera... Pam thinks we may need some more sound proofing in the cab and now has a new ring tone on her phone
The top hose that Patrick had cobbled together for the old radiator was fine with the new one, as were the 2 small circulation pipes to the manifold and the expansion tank. The bottom hose, on the other hand, turned out to be a nightmare due to the wierd angles involved and the lack of suitable hoses. Eventually I managed to get the right angle using 2 part hoses and an aluminium joining tube which was a bitch to fit but finally gave up in the end and joined up without any creases. Might buy a couple of Samco 45 degree bends and use a similar piece of pipe for the final version. For the moment though, it's water tight and it's full of coolant again.
Spent yet more time fixing cables securely out of the way, think all the under vehicle cables are now sorted, just the mass of cables behind the drivers seat to sort out now !
Pam was with me today so, once the rad was full of water, I fired it up so she could hear what it actually sounds like in the flesh rather than the narrow spectrum version on the video camera... Pam thinks we may need some more sound proofing in the cab and now has a new ring tone on her phone
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davew
- Chairman
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- Joined: Fri Jan 05, 2007 8:54 pm
- Location: Knaresborough
- Full Name: Dave White
After a quick trip to the auto factors this morning I set about the miriad of small jobs that still need sorting.
I started with the vacuum pipe for the brake servo, obviously the servo fitting and the engine fitting are completely different sizes. I used the new servo pipe purchased at the auto factors for the bulk of the pipe and fabricated a joiner/adaptor to link that to a short length of larger I/D pipe hooked up to the engine - no leaks and fully functioning.
Fitted a new horn in the same place as the TD5 Defender (had wondered what the vents were for in the light surround).
Used a none return valve as a joiner to hook the TD5 style washer bottle pipe to the original washer pipe - hopefully that will also stop the leak I always seem to get at extreme angles as it takes a fair amount of pressure to overcome the valve.
Fitted the military sprung bonnet clips to the new bonnet, the anti-burst latch and the rubber buffers. Gave up trying to use the old bonnet prop and ordered a TD5 one - don't need a prop for the MOT anyway !
Wired up the electric fans and adjusted the engine ECU to turn them on and off at the appropriate temperatures.
Made some new offset mounts for the expansion bottle so the bonnet clears it when it shuts.
Put the grill, front winch and bumper back on and fitted the spats back onto the front wing.
Rerouted the wiring for the fuel pump so I could refit the fuel tank cover, got the top and front of the cover fitted and run out of time - will fit the sides tomorrow.
For the first time I think the list of jobs that needs doing before the MOT is becoming manageable ! Quietly confident that it'll be ready for an MOT by the end of the day tomorrow... he said, fingers crossed
I started with the vacuum pipe for the brake servo, obviously the servo fitting and the engine fitting are completely different sizes. I used the new servo pipe purchased at the auto factors for the bulk of the pipe and fabricated a joiner/adaptor to link that to a short length of larger I/D pipe hooked up to the engine - no leaks and fully functioning.
Fitted a new horn in the same place as the TD5 Defender (had wondered what the vents were for in the light surround).
Used a none return valve as a joiner to hook the TD5 style washer bottle pipe to the original washer pipe - hopefully that will also stop the leak I always seem to get at extreme angles as it takes a fair amount of pressure to overcome the valve.
Fitted the military sprung bonnet clips to the new bonnet, the anti-burst latch and the rubber buffers. Gave up trying to use the old bonnet prop and ordered a TD5 one - don't need a prop for the MOT anyway !
Wired up the electric fans and adjusted the engine ECU to turn them on and off at the appropriate temperatures.
Made some new offset mounts for the expansion bottle so the bonnet clears it when it shuts.
Put the grill, front winch and bumper back on and fitted the spats back onto the front wing.
Rerouted the wiring for the fuel pump so I could refit the fuel tank cover, got the top and front of the cover fitted and run out of time - will fit the sides tomorrow.
For the first time I think the list of jobs that needs doing before the MOT is becoming manageable ! Quietly confident that it'll be ready for an MOT by the end of the day tomorrow... he said, fingers crossed
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davew
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- Location: Knaresborough
- Full Name: Dave White
Got a few more jobs ticked off the MOT list today. Got the fuel pump and filters fastened, finished off refitting the fuel tank cover and then emptied all the items that I've thrown in the back during the build. Put the spare wheel in the back and fastened it down so everything behind the cab is ready.
The radiator guy came over with the gearbox oil cooler (I'll fit that when it's back on the road) and the 4" diameter 90 degree hoses to connect the inlet pipe up. The last plan we had for the inlet pipe position was looking dubious but after a couple of hours of trimming the hoses a bit at a time I managed to find a position where the air filter doesn't catch the bonnet an the pipes don't foul the cooling fans. I'm not over happy with the result but it will do as a temporary measure until I come up with a better solution. I think I'll need to get someone to fabricate a manifold to attach to the front of the throttle body rather than using hoses. The throttle butterfly opening is only about 3 inches across whereas the body is 4 inches - seems pointless using 4 inch pipe.
The indicator repeater finally arrived for the drivers side wing so, with the inlet piped up, everything in front of the windscreen is ready.
I plucked up courage to tackle the rat's nest of wiring behind the driver's seat by disconnecting it all, mounting the fuse box, relays and the 2 ECUs onto the bulkhead then rerouting the wiring accordingly.
I cut a plate to cover all the holes in the cover between the seats that used to be filled by the battery cutout switch and the old gear lever.
With the wiring tidied and the holes filled in a major milestone had been reached - time to move my motor out of the top shed onto a ramp. It took a while to clear the debris, move the forklift, lawn mower, my old engine and box, another engine in bits that someone has bought and so on but eventually I got to drive down into the main workshop and took it for a quick spin around the paddock. Seems the speedo still isn't working despite the new cable so will have to investigate that but everything else seems fine. The cooling capabilities of the fans/radiator seem quite impressive, sat ticking over the fans came on at 87 degrees C and cooled it to 75 degrees in around 15 seconds.
Replaced the panhard rod bushes and called it a day with my motor sat on a four poster so I can get straight on with the exhaust mounts in the morning. Jobs list for the MOT - exhaust mounts, fix the speedo, fill up the transfer box, tighten the wheel nuts... looking good for an MOT late morning/early afternoon. I have a feeling she's running a bit lean at the moment although the lambda indicates a good mix, if I have time I'll investigate that before the MOT too. Might be that the lambda ecu is set up for the wrong sensor or something.
The radiator guy came over with the gearbox oil cooler (I'll fit that when it's back on the road) and the 4" diameter 90 degree hoses to connect the inlet pipe up. The last plan we had for the inlet pipe position was looking dubious but after a couple of hours of trimming the hoses a bit at a time I managed to find a position where the air filter doesn't catch the bonnet an the pipes don't foul the cooling fans. I'm not over happy with the result but it will do as a temporary measure until I come up with a better solution. I think I'll need to get someone to fabricate a manifold to attach to the front of the throttle body rather than using hoses. The throttle butterfly opening is only about 3 inches across whereas the body is 4 inches - seems pointless using 4 inch pipe.
The indicator repeater finally arrived for the drivers side wing so, with the inlet piped up, everything in front of the windscreen is ready.
I plucked up courage to tackle the rat's nest of wiring behind the driver's seat by disconnecting it all, mounting the fuse box, relays and the 2 ECUs onto the bulkhead then rerouting the wiring accordingly.
I cut a plate to cover all the holes in the cover between the seats that used to be filled by the battery cutout switch and the old gear lever.
With the wiring tidied and the holes filled in a major milestone had been reached - time to move my motor out of the top shed onto a ramp. It took a while to clear the debris, move the forklift, lawn mower, my old engine and box, another engine in bits that someone has bought and so on but eventually I got to drive down into the main workshop and took it for a quick spin around the paddock. Seems the speedo still isn't working despite the new cable so will have to investigate that but everything else seems fine. The cooling capabilities of the fans/radiator seem quite impressive, sat ticking over the fans came on at 87 degrees C and cooled it to 75 degrees in around 15 seconds.
Replaced the panhard rod bushes and called it a day with my motor sat on a four poster so I can get straight on with the exhaust mounts in the morning. Jobs list for the MOT - exhaust mounts, fix the speedo, fill up the transfer box, tighten the wheel nuts... looking good for an MOT late morning/early afternoon. I have a feeling she's running a bit lean at the moment although the lambda indicates a good mix, if I have time I'll investigate that before the MOT too. Might be that the lambda ecu is set up for the wrong sensor or something.
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davew
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An early finish today !
First job this morning was to try and get the in-car PC running so that I can start tuning it on the fly. After fitting the screen and running the necessary wiring I found myself in a catch 22 situation, the USB flash drive that I have all the ECU software loaded on draws too much power for the mini USB hub in the dashboard meaning I can have the flash drive but no keyboard and touch screen or I can have the keyboard and touchscreen without the flash drive... nett result was that after a couple of hours messing about I still have no way of adjusting the tuning with the vehicle moving. Relying on the "Megasquirt workstation" that Patrick cobbled together using a desktop PC and an old cryptotune station.
The speedo problem turned out to be due to the cable not being fully home at the back of the speedo so that was a nice simple fix.
Managed to weld/fabricate the exhaust mounts so, finally, I can get rid of the bit of wire supporting the silencer and the rag stopping the tail pipe rattling. No rattles now, just the sweetest V8 burble you ever heard.
Filled the transfer box, tightened the wheel nuts and spent a bit of time adjusting the fueling. Still not sure I believe what the lambda is telling me as it sounds to be running weak and the lambda shows it as running slightly rich. It's close enough for the moment though, I'll have another go at it once it's done a few miles and blown the cobwebs off the lambda.
A quick phone call and it was booked in for an MOT either late this evening or first thing in the morning so drove ver to the test centre and left it there... just waiting on a phone call now ! The "test drive" from Maddisons to the test centre revealed that I won't be using the throttle much on the road... the gearbox ECU needs some fine tuning as it kicks down way too early at the moment which makes it a bit jerky as you barely touch the throttle and it knocks it down a gear and gives you huge amounts of power at the same time. Will spend part of this evening reading the manuals for the gearbox ECU to figure out what I can set and how. I need to try and get a laptop or the in-car PC sorted for tomorrow too.
Assuming all goes well at the MOT, tomorrow will be spent tweaking the gearbox and engine settings on the road
First job this morning was to try and get the in-car PC running so that I can start tuning it on the fly. After fitting the screen and running the necessary wiring I found myself in a catch 22 situation, the USB flash drive that I have all the ECU software loaded on draws too much power for the mini USB hub in the dashboard meaning I can have the flash drive but no keyboard and touch screen or I can have the keyboard and touchscreen without the flash drive... nett result was that after a couple of hours messing about I still have no way of adjusting the tuning with the vehicle moving. Relying on the "Megasquirt workstation" that Patrick cobbled together using a desktop PC and an old cryptotune station.
The speedo problem turned out to be due to the cable not being fully home at the back of the speedo so that was a nice simple fix.
Managed to weld/fabricate the exhaust mounts so, finally, I can get rid of the bit of wire supporting the silencer and the rag stopping the tail pipe rattling. No rattles now, just the sweetest V8 burble you ever heard.
Filled the transfer box, tightened the wheel nuts and spent a bit of time adjusting the fueling. Still not sure I believe what the lambda is telling me as it sounds to be running weak and the lambda shows it as running slightly rich. It's close enough for the moment though, I'll have another go at it once it's done a few miles and blown the cobwebs off the lambda.
A quick phone call and it was booked in for an MOT either late this evening or first thing in the morning so drove ver to the test centre and left it there... just waiting on a phone call now ! The "test drive" from Maddisons to the test centre revealed that I won't be using the throttle much on the road... the gearbox ECU needs some fine tuning as it kicks down way too early at the moment which makes it a bit jerky as you barely touch the throttle and it knocks it down a gear and gives you huge amounts of power at the same time. Will spend part of this evening reading the manuals for the gearbox ECU to figure out what I can set and how. I need to try and get a laptop or the in-car PC sorted for tomorrow too.
Assuming all goes well at the MOT, tomorrow will be spent tweaking the gearbox and engine settings on the road
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davew
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It passed it's MOT
Initial impressions, I need a higher ratio transfer box ! Gearbox settings need fine tuning, especially at lower speeds 0-35 MPH is jerky with the gearbox constantly changing gear for some reason, it also kicks down way too early for such a powerful engine - I swear I span the front wheels at around 60MPH overtaking someone on the way home when it kicked down... which was a bit exciting to say the least.
Off to put the in-car PC back in with the software loaded and take a print out of the CompuShift manual (the gearbox ECU) so I can spend the afternoon ironing out the settings.
One slight hiccup on the way home when I got a phone call from Pam (following me) to tell me there was something hanging out of the exhaust... seems some of the main silencer wadding was making a bid fro freedom out of the tailpipe - pulled about 20 feet out and decided it was going to keep coming so cut it off, Pam tells me a further 5 feet or so blew out after we set off, will query it with the exhaust place at some point but, for now, no sign of any more.
Initial impressions, I need a higher ratio transfer box ! Gearbox settings need fine tuning, especially at lower speeds 0-35 MPH is jerky with the gearbox constantly changing gear for some reason, it also kicks down way too early for such a powerful engine - I swear I span the front wheels at around 60MPH overtaking someone on the way home when it kicked down... which was a bit exciting to say the least.
Off to put the in-car PC back in with the software loaded and take a print out of the CompuShift manual (the gearbox ECU) so I can spend the afternoon ironing out the settings.
One slight hiccup on the way home when I got a phone call from Pam (following me) to tell me there was something hanging out of the exhaust... seems some of the main silencer wadding was making a bid fro freedom out of the tailpipe - pulled about 20 feet out and decided it was going to keep coming so cut it off, Pam tells me a further 5 feet or so blew out after we set off, will query it with the exhaust place at some point but, for now, no sign of any more.
Congratulations!
So - is it a boy or a girl? And what's it called? Will it be at Frickley?
Re the wadding - some years ago you could buy motorcycle silencers which had easily removed wadding so that 'as supplied' they passed the noise tests... Heard of plenty of people taking it out, but I admit not ever heard of it blowing out! Maybe it's a similar idea?
So - is it a boy or a girl? And what's it called? Will it be at Frickley?
Re the wadding - some years ago you could buy motorcycle silencers which had easily removed wadding so that 'as supplied' they passed the noise tests... Heard of plenty of people taking it out, but I admit not ever heard of it blowing out! Maybe it's a similar idea?
Last edited by TwoSheds on Thu Sep 27, 2007 6:23 pm, edited 1 time in total.
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davew
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- Location: Knaresborough
- Full Name: Dave White
No sign of any more wadding, guess that bit was surplus to requirements...
Sorted the gearbox out, there are 2 speed sensors on the gearbox, the ECU installation guide said "for 4x4 vehicles use the sensor nearest the T/C" which I interpreted as Torque Convertor, turns out they meant Transfer Case Had to partially dismantle the tunnel to get the connector swapped over but the results were immediate. Instead of major changes to the gearbox settings I'm now back into minor tweaks and now need to undo some of the setting changes I made while trying to sort it out earlier.
Sorted the gearbox out, there are 2 speed sensors on the gearbox, the ECU installation guide said "for 4x4 vehicles use the sensor nearest the T/C" which I interpreted as Torque Convertor, turns out they meant Transfer Case
Had to partially dismantle the tunnel to get the connector swapped over but the results were immediate. Instead of major changes to the gearbox settings I'm now back into minor tweaks and now need to undo some of the setting changes I made while trying to sort it out earlier.Who is online
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