1 May 2007
Session 168 - Plenum chamber pattern
Well another month gone by. Waiting for parts means that my attention is back onto the plenum chamber project. So you saw my wooden frame a few days ago. So next I taped up the frame to enclose it and then injected expanding foam.
As you can see I got the volume just about right, anymore and it would have burst I think. This had to be left for 2 days to cure. Removed the tape and this is what it looks like.
My kitten was interested! So next I shall shape with sandpaper and fill any low spots with car body filler. In case you didn't realise this is the pattern from which I shall make a mould from which I will fabricate a GRP plenum chamber from and then retire from all the money people will pay me to make one for them!
2 May 2007
Session 169 - Clutch - hydraulics
My stainless braided hydraulic clutch hose arrived today. Since I went to work installing it tonight. Bled the clutch. Adjust the clutch pedal for maximum travel. Selected third gear and depressed clutch did not allow the car to freewheel meaning the clutch is not dis-engaging. Re-bled the clutch, tried again, still no release.
Bit perplexed what to do next I set about measuring the amount of movement the clutch slave cylinder exerts on the pushrod that operates the clutch release arm. It would seem that the slave cylinder is moving the pushrod some 9mm. As this is through a lever this operates the clutch release bearing by approximately 5mm. I have asked some fellow builders and it would seem that at least 8mm is required in which to dis-engage the clutch plate.
So tonight ended with a problem to resolve.
At ths point I am thinking the clutch slave cylinder is the problem. I have ordered another one from somewhere else to see if this resolves the problem.
4 May 2007
Session 170 - Plenum chamber pattern continues...
Did some more work on my plenum chamber pattern. I know this is probably getting boring now. But waiting for parts, waiting to source parts. Anyway a massive kit car show in on this weekend up at Stoneleigh. This is one of the year's biggest event.
Picture of pattern with its first coat of filler. Probably going to take three layers to get it just right. I also need to think about shaping the throttle inlet, this involve a piece of plastic pipe from a DIY store I am sure.
Yes, know it looks like a loaf of bread! But have you ever wondered why a loaf takes this shape, ah, not so stupid now is it?
30 minutes of sanding by hand brings out the beauty!
Stll some imperfections in the surface so I sprayed with paint and sanded to reveal the low spots and fill them in and re-sanded. It now looks like it is uneven but it is actuallly smoother than a baby's bottom. Next photo showing the start of the build up of the inlet from the throttle body. This is angle so that the intake charge is directed to the top of the plenum chamber.
The throttle inlet shaping continues...
The shaping of the throttle inlet is going to take a while!
11 May 2007
session 171 - Reverse light switch
Small but necessary job. Installed the reverse gear swtich in the gearbox. Loctited, copper crush washer and torqued to 18 ft/lbs. Tested it worked with my continuity tester. The electrical connectors are bullet type but the loom uses a connector so I shall have to change the connectors at some point.
12 May 2007
Session 172 - Clutch release problems
All this week I have been having clutch release problems.I have bled the system more times than I care to remember and many different methods. I took measurements, performed calculations and determined that the maximum travel the clutch slave pushrod could be actuated with the pedal travel is 15mm. This is based on the pedal travel being 30mm, the master cylinder bore being 5/8" and the slave cylinder bore of 7/8". Apparently to achieve proper clutch plate release requires the slave pushrod to be moved by 20mm. So this system is flawed from the start and I am confused as to why many others have built these cars have been able to get away with it. I can only think that for a standard clutch you can get away with less than 20mm and my clutch is an uprated item, although I was told that the standard clutch system would be adequate but then the Westfield is not quite a standard system to start with and maybe the tolerances are a little close.
I did some more mathes to establish which master cylinder would be able to cope. The trouble is the bigger the bore of the master the more work your left foot has to do! I wont bore you with the maths(can be found here) but essential the next bore size up is 0.700" and this is close as it could move the slave pushrod by 19mm, so I am going to the next size up again which is 0.750" (3/4) and this will move the slave pushrod 22mm. This master cylinder is a standard Land Rover item so I bought one from my local LR dealer and luckily he had one in stock.
I needed to cut down the master cylinder pushrod by 13mm to fit clevis of the clutch pedal.The orginal master cylinder looks a little worse for wear, might this explain the issue also! 90 minutes later I have installed the master cylinder and re-bled the system. Whoah, I have clutch release, albeit the pedal is stiffer but I am using my hand to push the pedal as I have no seat to sit in!
I also installted the clutch cover/bell housing mud shield as this sits between the cluch and the bell housing.
Photo showing the master cylinder, what you can see of it. Standard Land Rover (3/4" 0.750" bore). Not much room here!
Photo showing the clutch slave cylinder, a standard SD1 item (special 7/8" 0.875" bore). You can also make out my new bell housing mud shield.
I also did some more shaping of my plenum chamber pattern. Sprayed it black just to make it look tidy. Here's a photo of it placed on the engine.
I also found some bits of alliminium left over, now where do these go!
If you think the plenum pattern is finished, think again! I am spending about 1 hour a day filling, re-shaping a little here and there to make it perfect. Rather than bore you with loads of pictures in which you will barely notice a difference I shall post a picture at the end of this week.
27 May 2007
Session 173 - Plenum pattern finished
Today I decided that I would make a concerted effort in which to finish my plenum chamber design. I have spent many many hours on this over the last couple of weeks, most nights spent time sanding, filling, sanding, filling....
Today I also cleaned up an old fuel rail I got from Ebay, spayed with acid etch primer and finished with with double acylic black paint. The photos below show the chamber design and the fuel rail just underneath it.
28 May 2007
Session 174 - Refurbish Jaguar throttle body
With my plenum chamber design complete my attention is diverted to the dirty but good condition throttle body I purchased off ebay.
Here's a photo of it position against the plenum chamber design which will have a mounting flange fabricated. As you can see it is directed down so that air is directed toward the roof of the chamber.
I took plenty of pictures of the throttle body just in case I forgot where the bits go as I will need to take it all apart to refurbish, clean and paint.
I had actually cleaned the throttle body before I took the photos but need to clean up much better than this so next I took it all apart and cleaned with wd40, turps and finally alloy wheel cleaner. Then cleaned of with white spirit to degrease. I then painted with etch primer and then several coats of alluminium VHT paint.
This took me about 4 hours to do all this. The result can be seen below.
Go to June 2007