Archive for October, 2008

Colour Blind

Monday, October 27th, 2008

So, after much progress last week and the promise of continued progress, this weekend was a bit of a disaster!

I arrived home to a large box from the powder coaters. ‘Great’ I thought, ‘I can finish off the engine’. However when I opened it up to have a look, something was not quite right. Then it struck me, they had painted them black!!! I was not all that happy to say the least, not only was i expecting them to be orange, but when I sent them to the painters they were already black! They have now agreed to repaint them, but this is going to take another 2 weeks!

I then decided to put the engine into the cradle anyway, and to put that into the car. The diff was then bolted onto the frame, and one of the two tension bars was turned up.

Tension Bar

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Final (ish) Fitting Of The Column

Monday, October 20th, 2008

For some random reason, after finishing the engine, or at least as far as I could go anyway, I then decided to look at semi final fitting the column. Obviously everything needs to come off the chassis when I paint it, but the front ally work did not have any holes in it for the column to go through. So I attached the ally with a couple of cliquos (amazingly useful things), and drilled through the lower bush chassis mounts to mark the ally.

Drilling the Lower Bush

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Steering Wheel

Monday, October 20th, 2008

As I have mentioned before I am going to use flappy paddles on the back of the wheel to operate the gearbox. After doing the column, it was sort of progressive to sort out the steering wheel. My first issue were the paddles themselves. Well, that’s a bot mean to the paddles really, it was more that I have selected one of the smallest steering wheels available, so that fat bodgers like me can actually fit in the car, but this meant that when I held the paddle blocks on the back of the wheel I couldn’t fit my hands around the rim as the paddles were in the way. I contacted Neil and he said he could make me some smaller paddles to bolt on, as they are carbon bolt on bits you can have them any size you like, but that as a one off they might be quite expensive. I therefore decided to trim mine down and see if I could make them fit. If not I could always make ally ones myself.

 Paddle Mounting Location

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Finishing The Clutch

Monday, October 20th, 2008

So, after building up the basket and plates it was time to throw it into the engine. now, when I took the basket off, I undid the big nut with an airgun. That was all fine and worked a treat, but now I had to torque it up. And of course I don’t have the proper Suzuki tool for holding the basket, so i had to botch one up double snappy.So, after last weeks upsetting result of thinking I didn’t have the right spring plate, I got stuck in with the clutch. Not really too much to say as it pretty simple. The only slight difficulty was finding a method of holding the basket from turning when doing up the bolts. In the end I used 2 bits of steel in between the fingers as shown, clamped in the vice.

Basket In Vice

Torquing Up The Bolts

 I was told that after torquing up the bolts, it was sensible to tack weld them so there was no way of them coming lose. Not to sure about this as it seems like a one hit wonder, but I suppose I can easily, he hopes, just grind the tack off if I ever need to…. (famous last words!)

Welded Up Nuts
So, after building up the basket and plates it was time to throw it into the engine. now, when I took the basket off, I undid the big nut with an airgun. That was all fine and worked a treat, but now I had to torque it up. And of course I don’t have the proper Suzuki tool for holding the basket, so I had to botch one up double snappy.

Making The Tool

So some off cut angle and plate soon became the worlds most over engineered clutch basket holding tool! But hey, it shouldn’t brake!

Tool In Use
All Done

 The engine is now mechanically all done apart from the covers, which I should be getting back on Tuesday/Wednesday depending on posting times.

CAM Timing

Monday, October 13th, 2008

Next on the list for the engine was the CAM timing. The first problem that I came across was actually measuring the lift. The problem being that the valve is below the CAM, now when we do Porsche timing, as there is a rocker, there is no problem with access to the valve to measure lift. However as with the busa the CAM is above the valve you need a special curved probe to bend around the CAM. However nothing a bit of welding rod couldn’t sort, but then it was a little tricky keeping it in the same place on the valve bucket as the probe was now not really attached at either end and could slip, but with a bit of care it was sorted!

Measuring The Lift On Exhaust

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