Just Plain Silly!

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

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Crouchie_b
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Just Plain Silly!

Post by Crouchie_b » Sat Oct 10, 2020 11:59 am

Spent another day at Paul’s again this week but felt like another 2 steps forward & 1 back kind of day :roll:
I have a ad pop up on FaceAche last week for ceramic coating and as I’d been thinking about getting the exhaust manifold done I sent off an enquiry and was pleasantly surprised by the quote & speed of turn around promised. So job number 1 was take off the manifold which was test fitted with the turbo last visit, and package it up ready for the couriers to pick up. We’ll see if they live up to their promises in a couple of weeks - 1 step backward!

With the turbo back off the manifold, I made the inlet flange gasket & bolted it up with the billet alloy inlet, fitted the turbo exhaust outlet gasket & 2.5” casting & stainless elbow.The elbow also has Lamda bosses, a flex pipe and connect with v-bands, so hopefully will allow the exhaust to run through the standard route. I have the bits to run the same in 3” but think that would be to tight without some bulkhead mods but we’ll see when it’s in place.I’ve also fitted the turbo cooling & oil hoses, which are stainless braided flexi’s, and the alloy flanged oil return.
Turbo ready for final fitting when the manifold is back - 1 step forward!

At the front of the engine, last time I had fitted the tiny alternator and measured/guessed the pulley size. Ordered a Gates belt which was the nearest on the small size which as a fiver was a bargain, however the test fit showed that its too tight to fit so that will go on Paul’s hook of spares while I order the next one up. I also have a set of alloy SR20 pulleys which are an option is I want to convert back to multi-V belt but neither pulley spacer or the alloy trigger wheel sensor mount weren’t back yet so I can’t check if they would work. Neither forwards or backwards really so moved on to the inlet side!

The inlet is adapted to take 8 injectors and was originally going to be used with 8 standard injectors back when I first started with the project. Time & technology has moved on so i now have moved up to 440cc high impedance injectors. Fuel quantity shouldn’t be a problem, the Emerald ECU can control both inner & outer sets and high impedance removes the need for 8 ballast resistors.
I fitted the inner bank which fit into the existing injector holes and are held in place with the standard collars. A billet fuel rail was then drilled to push over the top end of the injector but needs taking out to 13.5mm for the O rings to seal and lack of the correct size stopped further progress.
The outer bank fit into an area of alloy added to the runners which has been drilled so the injectors fire straight at the inlet ports from about 100 mm further away from the inner bank. The holes drilled for the standard injectors fit the new ones so here the second billet fuel rail just needed redrilling to 13.5 mm again, fit the top of the new 440’s. Once the fuel rails are fitting snugly just I need to improve the fixing brackets to hole them in place for the 40-50 psi fuel pressure. :wink: Drill bit ordered - 1/2 step forward!
The throttle body I’m using is the one I used on the SST which I had rebored, made a brass butterfly plate for it & fettled the spindle. It takes the 200sx TPS but i had butchered the connector to use it in place of the standard on/off TPS on the SST. New TPS & connector ordered so it can be added to the engine loom when we get the engine in place. The rest of the inlet work is plumbing so measurements taken & various bits of black silicon ordered from ASH - 1/2 step forward.

A little trick I’ve picked up over the years is to use a white board to record project milestones & targets. As the car is at Paul’s, it didn’t feel like the done thing to rock up with my own whiteboard so I’ve started using the windscreen to write the jobs down on. This means that I can quickly remind myself of what’s next and rubbing off the completed jobs at the end of the day means, that on a day like Thursday was, I can leave feeling I have achieved something.

In other news, my trailer is now back with it’s new cover so in lieu of photos of the gold & black engine, here’s the yellow & black trailer :D
Attachments
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Crouchie_b

Modified SS1 Ti - Just Plain Silly https://www.scimitarweb.co.uk/sgwrs/viewtopic.php?t=26204
SST - Mission Improbable... https://www.scimitarweb.co.uk/sgwrs/viewtopic.php?t=846

efi_sprintgte
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Just Plain Silly!

Post by efi_sprintgte » Sat Oct 10, 2020 12:59 pm

More details on your trailer tent please, I like that design.


JC

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Crouchie_b
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Just Plain Silly!

Post by Crouchie_b » Sat Oct 10, 2020 1:48 pm

efi_sprintgte wrote:
Sat Oct 10, 2020 12:59 pm
More details on your trailer tent please, I like that design.
It’s a Brian James tilt-bed with a custom/hand built/cobbled togeather (delete as appropriate) 1” steel tubular frame.
There’s a better picture below of the frame before the new cover was made.
I bought it of e-bay from a guy who built it for his drag racer so don’t know where the frame came from but i do know that you can get 3/4” handrail & connectors of various types that may work, but welded tube would work just as well.
The cover was made to my spec by Stewart Canvas Ltd in Warrington https://stuartcanvas.co.uk/trailer-cover/
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E39D3565-BC16-4611-B62E-369170F21EE2.jpeg
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Crouchie_b

Modified SS1 Ti - Just Plain Silly https://www.scimitarweb.co.uk/sgwrs/viewtopic.php?t=26204
SST - Mission Improbable... https://www.scimitarweb.co.uk/sgwrs/viewtopic.php?t=846

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scimmy ben
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Just Plain Silly!

Post by scimmy ben » Sat Oct 10, 2020 2:07 pm

Ceramic coating in gold or black :)

Are you going to play with different injector locations on the rollers to see which gives best performance? One set of 440's provide enough fuel for 300bhp+ in the CA18 DET.



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Crouchie_b
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Just Plain Silly!

Post by Crouchie_b » Sat Oct 10, 2020 4:55 pm

scimmy ben wrote:
Sat Oct 10, 2020 2:07 pm
Ceramic coating in gold or black :)
Gold of course :lol:
scimmy ben wrote:
Sat Oct 10, 2020 2:07 pm
Are you going to play with different injector locations on the rollers to see which gives best performance?
Yes, once the car is set up and running, the plan is to play with the point that the outboards switch in and the percentages of each.
May end up changing the to smaller ones on the inboard, outboard or both?


Crouchie_b

Modified SS1 Ti - Just Plain Silly https://www.scimitarweb.co.uk/sgwrs/viewtopic.php?t=26204
SST - Mission Improbable... https://www.scimitarweb.co.uk/sgwrs/viewtopic.php?t=846

efi_sprintgte
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Just Plain Silly!

Post by efi_sprintgte » Sat Oct 10, 2020 7:25 pm

Crouchie_b wrote:
Sat Oct 10, 2020 1:48 pm
efi_sprintgte wrote:
Sat Oct 10, 2020 12:59 pm
More details on your trailer tent please, I like that design.
It’s a Brian James tilt-bed with a custom/hand built/cobbled togeather (delete as appropriate) 1” steel tubular frame.
There’s a better picture below of the frame before the new cover was made.
I bought it of e-bay from a guy who built it for his drag racer so don’t know where the frame came from but i do know that you can get 3/4” handrail & connectors of various types that may work, but welded tube would work just as well.
The cover was made to my spec by Stewart Canvas Ltd in Warrington https://stuartcanvas.co.uk/trailer-cover/
Can’t see that adding much weight to the rig, nice one.


JC

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reliant-reviver
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Just Plain Silly!

Post by reliant-reviver » Tue Oct 13, 2020 11:03 am

Be interested to see how you get on with the "ceramic coating" I had a very similar thing with getting hooked by an ad on Facebook, made contact but didn't get a price back. To my understanding the outfit in question was offering a sprayed coating of the paint from cerakote - https://www.cerakote.com, which a bit of reading around online seems to suggest is a fairly good product. I'm just unsure as to whether it would last well in a turbo manifold application.

Ultimate solution would be having it turned around by zircotec - but the cost is eye watering. It is however a hot plasma type application to my understanding and quite different from any paint type thing.

Anyway, all looking good, bet it's nice to see it progressing?


Philip Andrew.
'74 Robin Super Saloon, '84 SS1 1300, '86 SS1 1800ti, '87 SS1 1300
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Crouchie_b
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Just Plain Silly!

Post by Crouchie_b » Tue Oct 13, 2020 12:40 pm

reliant-reviver wrote:
Tue Oct 13, 2020 11:03 am
Ultimate solution would be having it turned around by zircotec?
That’s good news then because that’s where it is!😎

It’s not going as quickly as I’d like but that’s down to me & the time I can spare for the build. Still, it’s going forward.


Crouchie_b

Modified SS1 Ti - Just Plain Silly https://www.scimitarweb.co.uk/sgwrs/viewtopic.php?t=26204
SST - Mission Improbable... https://www.scimitarweb.co.uk/sgwrs/viewtopic.php?t=846

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Crouchie_b
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Just Plain Silly!

Post by Crouchie_b » Fri Oct 23, 2020 8:54 pm

Progress & shiny bits!

The exhaust manifold arrived back today and it looks as sexy as...
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Volcanic Ceramic Coating so hopefully it’s good for a little less heat under the bonnet.
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Great finish & the faces were still immaculate. Very pleased with it.
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Only finger tight at the moment but that’s job one for next time!

The trigger wheel bracket (jigsaw) has been assembled by the welder, although his feedback is not able to be published without offending some and I gather he’s not keen on doing it again? It’s very light being made out of ally but I’m not sure if its stiff enough so it may come off next time to go to my local guy to add a bit more support.
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It flexes a gnats wotsit when you put pressure on the front right corner of the mounting plate but another triangular section on the back side should sort it.

The pulley spacer was also back and fits this time so I was able to finalise the alternator positioning and I’ve now got some adjustment. The pulley centres can now be adjusted to move about 20mm further apart so its not a lot but it should be enough to get a belt on and under tension. But I do need to repaint the bracket after persuading it to sit in the right place. Corky’s old trigger wheel while be painted (Gold) and bolted to the front.

Last time, I couldn’t get the injectors to seat in the billet fuel rails because the holes were too tight to take the O rings.
A 13.5mm drill bit, a counter sink bit and a bit of lube and today we ended up with this...
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The injectors fit nice and tight into the rail and the inlet manifold so it was on to a bit of CAD work to design the brackets to hold the rails in place when we introduce 3 bar of fuel to the equation!
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Obviously CAD stands for Cardboard Aided Design and I’ve found that the Amazon delivery envelopes make really good templates! The 2 base plates bolt on to the original fuel rail mounts and when tightened down the ‘hooks’ will pull the rail down and clamp it in place. The templates will go to the local fabricator and be made out of something suitably none-flexible. If I go with steel, I’ll fit a thin strip of rubber or similar between the hook & rail so stop any wear on the ally but I’m not sure what’s best yet.

Thanks for reading & stay safe.


Crouchie_b

Modified SS1 Ti - Just Plain Silly https://www.scimitarweb.co.uk/sgwrs/viewtopic.php?t=26204
SST - Mission Improbable... https://www.scimitarweb.co.uk/sgwrs/viewtopic.php?t=846

Benc
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Just Plain Silly!

Post by Benc » Fri Oct 23, 2020 9:54 pm

That manifold is the dogs dodars :mrgreen:



efi_sprintgte
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Post by efi_sprintgte » Sat Oct 24, 2020 7:29 am

8) 8)


JC

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philhoward
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Post by philhoward » Sat Oct 24, 2020 7:46 am

If you think the crank sensor bracket might be able to move even a tiny bit, then you can be sure it will - and you will have problems.

Ask Team Crosby...


Phil Howard
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Post by nickkeyser » Sat Oct 24, 2020 8:01 am

Looks great! Love the ceramic coating.

Agree with Phil RE the crank sensor bracket. Mines made from alloy plate (same thickness as street signs...) and thick alloy angle, but at a certain RPM it was vibrating and throwing errors on the dyno. It’s not noticeable when driving as it’s in the transient area of the Rev range, but then I’m never cruising along...


SSSC Champion 2019

SS1 CVH 1600Ti

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philhoward
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Post by philhoward » Sat Oct 24, 2020 8:11 am

If you’re using aluminium for the bracket, you should be using 6mm or 1/4”, and triangulated. Especially at that distance. That one will vibrate at an unknown frequency (I say that as I don’t know how to calculate it :mrgreen: ) and cause problem.

TBH if you can’t pick the engine up with it, it isn’t strong enough..


Phil Howard
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SS1 1600 Rooster Turbo; Sabre Mk1.5, Sabre Mk2
SS1 Racer
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.

efi_sprintgte
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Post by efi_sprintgte » Sat Oct 24, 2020 9:58 am

Yeah we had issues in the early days of Beastie, ended up welding a 10mm thick bar with a hole in it to the timing cover and using a Zetec sensor that can be shimmed to set up trigger distance.


JC

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