E150 UOL rebuild - End of project :-)

If you have a long-term project and would like to share/document progress, this is for you.

Moderators: scimjim, Lukeyboy46, erikscimitardemon, Roger Pennington, philhoward

User avatar
td99
RSSOC Member
Posts: 1805
Joined: Sat Jun 30, 2007 9:37 pm
Location: Eindhoven, Netherlands
Has thanked: 17 times
Been thanked: 33 times

Re: E150 UOL rebuild - nice and shiny!

Post by td99 » Fri Sep 23, 2016 8:18 am

Thanks guys, I'll be looking for some LH drill bits then. Sound like a good investment.


Trevor - 1800Ti daily driver
1800Ti DET project, RAV4

User avatar
td99
RSSOC Member
Posts: 1805
Joined: Sat Jun 30, 2007 9:37 pm
Location: Eindhoven, Netherlands
Has thanked: 17 times
Been thanked: 33 times

Re: E150 UOL rebuild - nice and shiny!

Post by td99 » Sat Sep 24, 2016 7:36 pm

After ordering aforesaid LH drill set, I realized that a real stud wasn't necessary for my purposes - just to maintain flatness of flange while re welding ex manifold.
So, patience being my middle name :P , I decided to drill a hole in teh stud to accommodate an 8 mm stud.
So I centre-punched the broken bit, and started to drill a small (too small!) 2.5 mm hole at the centre, this by using column drill on (too loosely mounted) cyl head. So some vibration came along and I think relative movement/vibration between column drill and cyl head resulted in broken drill :cry:
Bigger drill did not want to remove its smaller brother!

So I got out the TIG and built up a bubble of hot iron on top of the recessed stud, then welded an 8 mm bolt to that bubble.
allowed it to cool off a bit but while still quite hot tried it with spanner. Could move stud in but not out.
Repeated "caressing" back and fro with longer spanner finally had pleasant result and it's out!
Attachments
2016-09-24 19.53.43 (Mobile).jpg
2016-09-24 19.53.43 (Mobile).jpg (59.85 KiB) Viewed 1305 times


Trevor - 1800Ti daily driver
1800Ti DET project, RAV4

User avatar
td99
RSSOC Member
Posts: 1805
Joined: Sat Jun 30, 2007 9:37 pm
Location: Eindhoven, Netherlands
Has thanked: 17 times
Been thanked: 33 times

Re: E150 UOL rebuild - nice and shiny!

Post by td99 » Wed Dec 28, 2016 6:24 pm

Decided to have another go at exhaust manifold a couple of days ago. From the second manifold I have, I cut the piping from the flange using the plasma cutter and then cleaned it up with the grinder. Quite amazing how the openings in the flange mismatch the ports of the cylinder head. I have a spare cylinder head to which I can bolt the flange to make sure that it remains flat while welding. I used rings cut from copper water pipe around the studs to ensure good centering. However, while manually positioning the rest of the exhaust manifold against the flange, I realized that I was creating another Ba**tard nut. One even worse than the original ET version. Tilting of the pipework relative to the flange can possibly alleviate this situation, maybe also using small diameter nuts and a shortened stud. I'll have to measure under-bonnet dimensions to see how this all fits with the turbo attached. The photo makes it look beter than the situation is in reality!!! Oh how the camera lies!

I would appreciate input from anybody who's actually done this to a DET manifold.
Attachments
2016-12-28 19.13.52 (Custom).jpg
2016-12-28 19.13.52 (Custom).jpg (45.01 KiB) Viewed 1204 times


Trevor - 1800Ti daily driver
1800Ti DET project, RAV4

User avatar
CNHSS1
RSSOC Member
Posts: 14597
Joined: Tue Aug 22, 2006 5:13 pm
Location: Shrewsbury, Shropshire
Has thanked: 428 times
Been thanked: 370 times
Contact:

Re: E150 UOL rebuild - nice and shiny!

Post by CNHSS1 » Wed Dec 28, 2016 6:34 pm

Nissan nuts are smaller diameter Trevor, gives a tad more clearance if it helps


Racing is life, everything before and after, is just waiting--Steve McQueen
6 time Class Champ, 2006 & 2014 SSSC Champion

RIP Batmobile, await the Rise of Dark Knight 8)
Sabre 'Light Sabre' 360hp!!
Image

User avatar
Corky
RSSOC Member
Posts: 11370
Joined: Sun Sep 24, 2006 5:02 am
Location: Macclesfield
Has thanked: 295 times
Been thanked: 229 times

Re: E150 UOL rebuild - nice and shiny!

Post by Corky » Wed Dec 28, 2016 7:28 pm

It was the same on my (now team Oakes) DET. It is the new b'stard nut :lol:

I used a flange nut that took a 12mm spanner, which made it a tad easier to get an open ended spanner on. But IIRC the last time I stripped it down I lost that nut :oops: and used a 13mm flange nut. The trick was to fit that one first, as when the manifold is against the head you can't get the nut onto the stud (as your photo shows). TBF it's not a problem when it's all fitted and working. And it was a lot easier to fit than the notorious 8v manifold.


Steve
Current:- SS1 Ti RG sprint car, Honda S2000, VW Touareg 3.0 V6
Prev:- Sabre Ti, 3xSS1 Ti, SS1 16v Turbo Racer, 5XGTC, 2XSE6B, 2XSE5A, 2XV6 Coupe, Sabre 6
Project Threads & YouTube

“It's not the winning, it's the taking apart that counts"

User avatar
philhoward
RSSOC Member
Posts: 25821
Joined: Tue Aug 29, 2006 5:41 pm
Location: Staffs, UK
Has thanked: 78 times
Been thanked: 707 times
Contact:

Re: E150 UOL rebuild - nice and shiny!

Post by philhoward » Wed Dec 28, 2016 8:46 pm

Crazy question but..

If the stud was another 50-60mm longer, would it miss the tubing? If so, then I've an idea.


Phil Howard
Scimitarweb Forum Admin
SS1 1600 Rooster Turbo; Sabre Mk1.5, Sabre Mk2
Previous: SE5/5a/SS1 No.1/SS1 Rooster/SS1 1800Ti/SE5a 24 Valve
http://www.ss1turbo.com
Never try and argue with an idiot. They drag you down to their level, then beat you based on experience.

User avatar
td99
RSSOC Member
Posts: 1805
Joined: Sat Jun 30, 2007 9:37 pm
Location: Eindhoven, Netherlands
Has thanked: 17 times
Been thanked: 33 times

Re: E150 UOL rebuild - nice and shiny!

Post by td99 » Wed Dec 28, 2016 9:17 pm

philhoward wrote:Crazy question but..

If the stud was another 50-60mm longer, would it miss the tubing? If so, then I've an idea.
I fear not, but will have a good look tomorrow. I guess you are thinking of the tubular fixings of taps to draining boardds etc - good idea Phil!


Trevor - 1800Ti daily driver
1800Ti DET project, RAV4

User avatar
td99
RSSOC Member
Posts: 1805
Joined: Sat Jun 30, 2007 9:37 pm
Location: Eindhoven, Netherlands
Has thanked: 17 times
Been thanked: 33 times

Re: E150 UOL rebuild - nice and shiny!

Post by td99 » Wed Dec 28, 2016 9:18 pm

Another idea I had was a stepped stud, so using an 8mm thread/nut to fix, as it's at bottopm, thus only to crimp gasket. not to take load of manifold+ Turbo


Trevor - 1800Ti daily driver
1800Ti DET project, RAV4

User avatar
td99
RSSOC Member
Posts: 1805
Joined: Sat Jun 30, 2007 9:37 pm
Location: Eindhoven, Netherlands
Has thanked: 17 times
Been thanked: 33 times

Re: E150 UOL rebuild - nice and shiny!

Post by td99 » Wed Dec 28, 2016 9:21 pm

CNHSS1 wrote:Nissan nuts are smaller diameter Trevor, gives a tad more clearance if it helps
Have some of them but as I said, camera lies, even the small Nissan nut would be difficult, although probably possible with Corky's approach to fit first.


Trevor - 1800Ti daily driver
1800Ti DET project, RAV4

User avatar
td99
RSSOC Member
Posts: 1805
Joined: Sat Jun 30, 2007 9:37 pm
Location: Eindhoven, Netherlands
Has thanked: 17 times
Been thanked: 33 times

Re: E150 UOL rebuild - nice and shiny!

Post by td99 » Wed Dec 28, 2016 10:30 pm

td99 wrote:
philhoward wrote:Crazy question but..

If the stud was another 50-60mm longer, would it miss the tubing? If so, then I've an idea.
I fear not, but will have a good look tomorrow. I guess you are thinking of the tubular fixings of taps to draining boardds etc - good idea Phil!
Went to Garage and checked it out: an extended stud will hit the manifold so that is a "no-go".


Trevor - 1800Ti daily driver
1800Ti DET project, RAV4

User avatar
scimjim
RSSOC Member
Posts: 38575
Joined: Sun Oct 01, 2006 10:08 pm
Location: Gloucester
Has thanked: 155 times
Been thanked: 1052 times

Re: E150 UOL rebuild - nice and shiny!

Post by scimjim » Wed Dec 28, 2016 10:34 pm

Will a socket screw fit?


Jim King

SECURE DRY STORAGE FOR YOUR SCIMITAR

Current: SE5 (8Ball), TI SS1 (snotty), 1600 SS1 (G97), 1600 SS1 (C686CCR), 2.5TD SE5a (diesel 5a), 6 x random other SS1s.
Previous: SE5, 3 x SE5a, 2 x SE6a, 3 x SE6b, GTC, 2.9i GTC, 3 x 1600 SS1, 1300 SS1, Mk1 Ti Sabre, Mk1.5 CVH Sabre
Chief mechanic for: 1400 K series SS1 (Megan3), 1400 CVH EFi SS1 (Grawpy), 1300 SS1 (Number One) & Sarah's coupe.
CURE THE FAULT - NOT THE SYMPTOMS

User avatar
scimjim
RSSOC Member
Posts: 38575
Joined: Sun Oct 01, 2006 10:08 pm
Location: Gloucester
Has thanked: 155 times
Been thanked: 1052 times

Re: E150 UOL rebuild - nice and shiny!

Post by scimjim » Wed Dec 28, 2016 10:48 pm

td99 wrote:Quite amazing how the openings in the flange mismatch the ports of the cylinder head..... I used rings cut from copper water pipe around the studs to ensure good centering.
If the ports are that misaligned and the bolt holes that oversize, could you not offset the manifold to give maximum clearance on that stud?

Or in extreme, can you cutout and scallop the exhaust?


Jim King

SECURE DRY STORAGE FOR YOUR SCIMITAR

Current: SE5 (8Ball), TI SS1 (snotty), 1600 SS1 (G97), 1600 SS1 (C686CCR), 2.5TD SE5a (diesel 5a), 6 x random other SS1s.
Previous: SE5, 3 x SE5a, 2 x SE6a, 3 x SE6b, GTC, 2.9i GTC, 3 x 1600 SS1, 1300 SS1, Mk1 Ti Sabre, Mk1.5 CVH Sabre
Chief mechanic for: 1400 K series SS1 (Megan3), 1400 CVH EFi SS1 (Grawpy), 1300 SS1 (Number One) & Sarah's coupe.
CURE THE FAULT - NOT THE SYMPTOMS

User avatar
CNHSS1
RSSOC Member
Posts: 14597
Joined: Tue Aug 22, 2006 5:13 pm
Location: Shrewsbury, Shropshire
Has thanked: 428 times
Been thanked: 370 times
Contact:

Re: E150 UOL rebuild - nice and shiny!

Post by CNHSS1 » Wed Dec 28, 2016 10:54 pm

Ideally the manifold ports should be oversize compared to the head ports, so some offsetting won't be an issue.


Racing is life, everything before and after, is just waiting--Steve McQueen
6 time Class Champ, 2006 & 2014 SSSC Champion

RIP Batmobile, await the Rise of Dark Knight 8)
Sabre 'Light Sabre' 360hp!!
Image

User avatar
nickkeyser
RSSOC Member
Posts: 2913
Joined: Thu Aug 28, 2008 2:58 pm
Has thanked: 36 times
Been thanked: 49 times

Re: E150 UOL rebuild - nice and shiny!

Post by nickkeyser » Wed Dec 28, 2016 11:17 pm

scimjim wrote:
td99 wrote:Quite amazing how the openings in the flange mismatch the ports of the cylinder head..... I used rings cut from copper water pipe around the studs to ensure good centering.
If the ports are that misaligned and the bolt holes that oversize, could you not offset the manifold to give maximum clearance on that stud?

Or in extreme, can you cutout and scallop the exhaust?
You want to dowel the manifold to the head in the optimum position if there's much 'adjustment' on the bolt holes.


SSSC Champion 2019

SS1 CVH 1600Ti

User avatar
CNHSS1
RSSOC Member
Posts: 14597
Joined: Tue Aug 22, 2006 5:13 pm
Location: Shrewsbury, Shropshire
Has thanked: 428 times
Been thanked: 370 times
Contact:

Re: E150 UOL rebuild - nice and shiny!

Post by CNHSS1 » Thu Dec 29, 2016 11:03 am

The manifold stud holes are usually 2mm oversixe as 5heres a lot of expansion. The heads ally,steel studs and stainless manifold which will be orange at full chat so you cant dowel multiple times like a NA manifold or it'll fail. One dowel would be ok I guess


Racing is life, everything before and after, is just waiting--Steve McQueen
6 time Class Champ, 2006 & 2014 SSSC Champion

RIP Batmobile, await the Rise of Dark Knight 8)
Sabre 'Light Sabre' 360hp!!
Image

Post Reply

Return to “Project Progress”