1972 1600SSS from New Zealand

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broke
Posts: 177
Joined: 04 Sep 2003 01:07
Location: New Zealand
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Re: My 4-door "budget build" - Warning, camera phone pics!

Postby broke » 04 May 2017 04:37

Good point Byron. The old me would be taking the diff straight apart and resetting to 45, but I've found that the only way to keep things moving is to let go of some of my perfectionism and deal with things as they crop up. I plan on running some nice sticky tyres and if I do ever eventually drive this thing I'll be flogging it mercilessly so if I can't tame it with friction modifier then I guess I'll deal to it later.

I was also a tad concerned about losing strength in the crossmember with the big hole, but I've yet to hear of a failure caused by it.

Thanks for your comments guys, it all helps keep the motivation levels up.
The IDx 10 concept is based on the 510 in the same way that the urinating I was doing last night was based on a 30 yr old single-malt scotch.
-McWicked

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broke
Posts: 177
Joined: 04 Sep 2003 01:07
Location: New Zealand
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Re: My 4-door "budget build" - Warning, camera phone pics!

Postby broke » 20 May 2017 01:17

Weighed up the pros and cons/potential risks and decided to go for a surge tank instead of an in-tank pump. Of course no off the shelf surge tank will fit in the space I have available underneath the car, so I'm having to make one.

First step was to have a quick measure, attempt to bend some 5mm alloy plate in the shop press at work and fail miserably. Ended up making a ghetto vice-mounted press brake thing out of some 50x70 angle iron and Bunnings hinges.
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You'd think bending this stuff would be easy, but it actually takes a lot of force to bend. Surprisingly the pieces turned out really nice, shame I scarred them up so badly with my previous attempts. I'll definitely keep this bending tool and use it for brackets etc. in the future.

Also my JIC weld ons arrived from aliexpress today. When I'm not so poverty stricken I'll get some more argon and try to get back in the groove of AC TIG welding. No excuses really after I bought the fancy machine and everything.

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The IDx 10 concept is based on the 510 in the same way that the urinating I was doing last night was based on a 30 yr old single-malt scotch.
-McWicked

User avatar
broke
Posts: 177
Joined: 04 Sep 2003 01:07
Location: New Zealand
Contact:

Re: My 4-door "budget build" - Warning, camera phone pics!

Postby broke » 20 May 2017 01:25

Did some welding today. It's not good enough for Weld Porn or anything, but it's not bad enough for "Welding Fails" either.
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You can see the space I'm aiming to fit it into here. Hoses will be cramped, but I'll make it work somehow. Also if I ever do this again I'm going to use those weld on UN o-ring bosses, as it's damn hard to get the torch into the right spot when you have two male fittings side by side.
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Then welded this mounting strap on top. Still need to get an alloy fuel pump mount and weld it to this, then buy fuel pumps and start plumbing them in. Nabbed lots of R14 teflon hose before I left my old job (I used to work in the hydraulics industry), so that should help keep costs down.
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The IDx 10 concept is based on the 510 in the same way that the urinating I was doing last night was based on a 30 yr old single-malt scotch.
-McWicked

User avatar
broke
Posts: 177
Joined: 04 Sep 2003 01:07
Location: New Zealand
Contact:

Re: 1972 1600SSS from New Zealand

Postby broke » 08 Aug 2017 14:49

Finished my surge tank, bought a Bosch style fuel pump and bracket and welded the bracket directly to the tank. Mounted the tank semi-permanently then mounted up the Carter lift pump off the spare wheel well. It hangs a tad lower than I'd like, although it's not as low as the spare wheel well. I may decide it needs a shield of some sort in the future.

Mounted up some 45 degree bulkhead fittings through the body forward to the surge tank and EFI pump. There's a bit of a no-man's land above where the axle will be so I will probably have to bend and flare some bundy tubing for that area. I'm out of $$$ for a while so that will have to wait.
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I enlarged the rear crossmember exhaust hole in the meantime
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I'm doing the S15 6 speed to L series gearbox conversion. Most of it looked pretty good and within spec, the bearings seem perfect apart from one needle roller. I do need some new baulk rings, I ordered the first lot of outer baulk rings and when they arrived I was pleasantly surprised to see that they came with the inner baulk ring and synchro cone too. If I'd known that I wouldn't have wasted all that time measuring the clearances between them.
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The IDx 10 concept is based on the 510 in the same way that the urinating I was doing last night was based on a 30 yr old single-malt scotch.
-McWicked

User avatar
broke
Posts: 177
Joined: 04 Sep 2003 01:07
Location: New Zealand
Contact:

Re: 1972 1600SSS from New Zealand

Postby broke » 08 Aug 2017 16:36

More gearbox stuff - I was expecting the countershaft to have the usual damage from 4th gear overcoming the circlip and the resulting carnage, as I bought the gearbox cheap from a drifter advertised with difficulty shifting into some gears.
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Surprisingly they had zero signs of damage in that area. However, it soon became apparent that the real issue was that these gearboxes use a DU bush in the shift fork where it slides on the selector rod. In this instance one of the bushes for the 2/3 fork had managed to drop right out! The other one only needed a minor bump to remove too.

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I suspect the cause of this was using a GL5 gear oil had eaten away at the bronze and that had caused the bush to disintegrate to the point where it just fell out. This would also explain the excessive wear on the brass baulk rings.

The DU bushes don't seem to be available anywhere in the correct size. They're 18mm OD and 15mm ID, I did try using a 15x17 bush with some shim stock wrapped around the outside but it wasn't satisfactory. I now own a lathe, so I machined my own full length bush out of UHMW plastic. It didn't machine very nicely and to make matters worse when I tried to reuse the old bushes I used this Loctite compound which made it impossible to press them out. I ended up machining a rod to go through the fork so I could chuck it on the lathe and slooooowwwly bore out the old bush.
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Got there in the end though. Started to cut the bellhousings too, I still have a lot of trimming to go before I can start tacking them together.
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Also got a NOS E9 BMW FPR without a vacuum port for free. I wanted one without the port as I expect the ITB's won't give a consistent enough signal to make having one worthwhile.
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The IDx 10 concept is based on the 510 in the same way that the urinating I was doing last night was based on a 30 yr old single-malt scotch.
-McWicked


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