Category: IPRA AE86

Not much to report for the weekend. Was out crewing for a mate at a kart meet on Saturday.

Put the interior back in today, and had an hour or so free so i machined up this:

[img]http://gallery2.plebeians.net/d/32749-2/1000001115.JPG[/img]

Still waiting on the brake fittings so i can finish that off. Hopefully that will all be done tomorrow night.

Big update now. Car is all back together, and headed off to be tuned yesterday. Done the main power tune, and im pretty happy with how its going sofar. Getting some fine tuning today as well.

Engine looks like this with all the ancillaries bolted on:
[IMG]http://gallery2.plebeians.net/d/32769-2/1000001133.JPG[/IMG]

Ill probably see if i can put some heat shielding on the exhaust as well, gets quite toasty atm.

Last weekend i went out and crewed for a mate when he was karting, and noticed the exhaust mounts which they use on the karts. Figured i can put this to good use, and rigged it up on the car to hold the exhaust up:
[IMG]http://gallery2.plebeians.net/d/32776-2/1000001131.JPG[/IMG]

Going to have to shift it a bit though, because it scrapes on the trailer and knocks off the springs. Dirt cheap though, $15 for the bracket and springs.

I finished setting up the front brakes, and so they look like this:
[IMG]http://gallery2.plebeians.net/d/32777-2/1000001132.JPG[/IMG]

Also got braided lines made up all around, thats the red blingy bit which you can see in the background.

Had to setup the pedal box again, and properly, so i machined up some spacers to seat the clevises in the right spot on the bar:
[IMG]http://gallery2.plebeians.net/d/32793-2/1000001123.JPG[/IMG]

Need to put some zipties on the cable sheath though, it moves around a bit.

The custom straight clutch pedal was rebent to be a bit more comfortable too:
[IMG]http://gallery2.plebeians.net/d/32789-2/1000001125.JPG[/IMG]
No more pesky clutch pedal running around the other side of the steering column.

Now one of the problems with bleeding dual master setups is theoretically you need to bleed both front and rear at the same time, as commonly the bias bar binds up on the clevis when you relieve pressure on only one of the circuits. This means that you cant push the piston all the way down and commonly get air stuck in there. So the way to fix that is bleeding both front and rear at the same time. But i didnt have two mates to come around at 1am to help with that, so i built a vacuum bleeder:
[IMG]http://gallery2.plebeians.net/d/32801-2/1000001137.JPG[/IMG]

Worked a treat, got pressure up enough in the lines to get it on the dyno yesterday, which was exactly what i wanted. Undoubtably there is still air all through the lines, but ill flush that out soon with a couple of mates.

I only have a tiny list of things to do before the next round, which is in a weeks time. This time next week i should be out testing on the Friday practice at Mallala.

[IMG]http://gallery2.plebeians.net/d/32739-2/1000001095.JPG[/IMG]
Engine back in, thats all good.

On the downside the stupid brake master cylinders are 3/8-24 AN concave flare, as opposed to a standard brake inverted flare. Arrrghh. Need to find adaptors for that.

Finished screwing the engine together in the couple of hours i had over the weekend:
[IMG]http://gallery2.plebeians.net/d/32735-2/1000001091.JPG[/IMG]

That includes making the new alternator bracket, which puts the alternator in roughly the same spot as the RWD alternators, but with the right backspacing for a FWD alternator. Or realistically i could run different alternators as i can space it back and forwards as needed.
Oh and despite being made out of decent thickness plate it still comes in lighter than the stock part.

Also finished off the brake caliper bracketry:
[IMG]http://gallery2.plebeians.net/d/32731-2/1000001081.JPG[/IMG]
Mmmm 300mm brakes.

Oh and replaced all the fuel filters because of this:
[IMG]http://gallery2.plebeians.net/d/32733-2/1000001080.JPG[/IMG]

That was the pre-lift pump filter from the tank. Its completely warped and soft, which i think is from the E85. This is despite several people saying that they were able to run them just fine for months on E85. I call BS.

Using the same AE92 high pressure filter, but using an AU Falcon pre-lift pump filter as its roughly the right size and all metal. Hopefully its not too much of an obstruction.

10 days until tuning now. Need to get the engine back in, and the brakes and gauges setup. Too easy.

Little bit of progress, apart from being crook.

Pulled apart the rear end looking for a brake line leak. Turns out that one of the lines had a pinhole leak. Found that im definitely using my rear brakes too:
[IMG]http://gallery2.plebeians.net/d/32699-2/1000001072.JPG[/IMG]

Sending off the diff to get reset too, may as well while its out.

Built up all of the exhaust, but had to send it off for welding because my stupid TIG isnt holding an AC arc on stainless. Will have to experiment more later.
[IMG]http://gallery2.plebeians.net/d/32691-2/1000001071.JPG[/IMG]

Mounted up the brake reservoir:
[IMG]http://gallery2.plebeians.net/d/32695-2/1000001073.JPG[/IMG]

Oh and started machining out the recess for the brake caliper mounts on the lathe:
[IMG]http://gallery2.plebeians.net/d/32705-2/1000001075.JPG[/IMG]

Still hoping to get a mill soon so i can finish them off. I tried using a mates mill, but its really setup for cylinder heads and blocks, so its a ton bigger than i need and the milling bit is way bigger than the biggest radius i have.

Need to install the wideband, and finish putting in the wiring for the gauges. Should be pretty much ready to put the engine back in on the weekend.

Spent a little bit of time screwing the engine back together today:
[IMG]http://gallery2.plebeians.net/d/32687-2/1000001069.JPG[/IMG]

Gone back to a RWD outlet system, albeit one with most of the sensor bungs replaced with other sizes. The rear and upper water outlets are still off getting bungs welded into them. Plus i got back my cam covers the other day with the -6 bungs welded into them.

Plus building the exhaust, putting the one piece rear brake line back in, and bending bundy tube for the brakes.

Little update. Got my nopics to help with putting the brake masters in. The old righty tighty lefty loosey thing. So the masters are now mounted up:
[IMG]http://gallery2.plebeians.net/d/32679-2/1000001065.JPG[/IMG]

Just need to get some bundy hose and make up the brake lines for them.

Also mocked up the brake reservoir there, i dont have a drill which is small enough to get in there. Considering getting one of the angle drill adaptors, but even then not sure if it will be small enough.

This is what it looks like from above:

[img]http://gallery2.plebeians.net/d/32683-2/1000001064.JPG[/img]

Last option is to drill from the otherside through the strut tower, but even then it would be very tight with the drill.

Also picked up the caliper adaptors from the laser cutters this morning:
[IMG]http://gallery2.plebeians.net/d/32671-2/1000001067.JPG[/IMG]

Need to get 4mm milled off the mounting face, and then i can drill and tap them for the calipers.

New brake lines next week for the entire car too.

Got a bunch more stuff done over the weekend, notably i finished off the dual master pedal box:
[IMG]http://gallery2.plebeians.net/d/32659-2/1000001044.JPG[/IMG]
[IMG]http://gallery2.plebeians.net/d/32655-2/1000001045.JPG[/IMG]

And i modified an RT104 clutch pedal for the current setup, but it runs on the tunnel side of the column:
[IMG]http://gallery2.plebeians.net/d/32651-2/1000001049.JPG[/IMG]

Bolted it all in:
[IMG]http://gallery2.plebeians.net/d/32647-2/1000001053.JPG[/IMG]
[IMG]http://gallery2.plebeians.net/d/32643-2/1000001056.JPG[/IMG]

Cant put the masters in yet, because i dont have monkey arms long enough to hold the balance bar attachment thingys horizontal while winding the master cylinder on. Will do that in the week to come.

Also not sure as to which side ill be running the adjuster cable. If i run it towards the door it will have to run basically across the accelerator pedal, but if i run it the other way it will run under the clutch pedal…. Hard choice.

Picked up a bunch of stuff for the engine as well, new water pump rear half to take an integral thermostat, rather than having to run a remote setup like i was previously (less rubber pipes to break).

Doing a few other things simply to chase reliability as well.

On the new brake setup side of things i fabbed up a dummy bracket for the calipers, and then transferred it into CAD and have fired it off to a few laser cutters this morning. Hopefully i can get that done within the week and then do the last bits before bolting it all up.

After that i need new brake lines, and to build the new exhaust and its off for a tune.

Had a few minutes last night on my hands, so i got the engine setup on the stand:

[img]http://gallery2.plebeians.net/d/32623-2/1000001041.JPG[/img]

Plus i cleaned up some of the other parts for it so i can start putting it together soon.

Also modified an RT104 clutch pedal so it would fit on the other side of the steering column, hopefully in the right spot. Will see how it goes. Need to weld on the tube for the balance bar to the pedal and then it should be good to go in.

My box of bits arrived today too, despite AusPost being retarded, so i can put the new gauges and warning switches in as well. More on that later.

Oh and i trial fitted the new wing, what do you think?

[img]http://gallery2.plebeians.net/d/32619-2/1000001039.JPG[/img]

[QUOTE=TK;841154612]All done, you’ll have to set up the cam timing – I don’t have the backing plate for the base marks & I don’t have the water pump which will have to go on first.
The sump is just that beat to fuck one, it’s only on there to keep the dust out, will need an oil pickup as well, I only have the one to suit the alloy sump here.

For those interested some specs:

Head flow as posted earlier.
13:1 compression for E85
ARP main & head studs
Wiseco pistons & rings
H-beam rods
Tasman cup valves, shimless buckets & some big mofo cams & springs

These are a really simple, well designed engine, dirt cheap to build up as a competitive race engine.

Pics:

[IMG]http://i291.photobucket.com/albums/ll318/TK383/IPRA%204AGE/P6190145.jpg[/IMG]

[IMG]http://i291.photobucket.com/albums/ll318/TK383/IPRA%204AGE/P6190147.jpg[/IMG]

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[IMG]http://i291.photobucket.com/albums/ll318/TK383/IPRA%204AGE/P6190152.jpg[/IMG]

[IMG]http://i291.photobucket.com/albums/ll318/TK383/IPRA%204AGE/P6190153.jpg[/IMG]

[IMG]http://i291.photobucket.com/albums/ll318/TK383/P6190159.jpg[/IMG]

[IMG]http://i291.photobucket.com/albums/ll318/TK383/P6190158.jpg[/IMG]

[IMG]http://i291.photobucket.com/albums/ll318/TK383/P6190157.jpg[/IMG]

[IMG]http://i291.photobucket.com/albums/ll318/TK383/P6190156.jpg[/IMG]

[IMG]http://i291.photobucket.com/albums/ll318/TK383/P6190155.jpg[/IMG]

[IMG]http://i291.photobucket.com/albums/ll318/TK383/P6190154.jpg[/IMG][/QUOTE]