SRowells Black Rallye

[Eeyore]

Day two of lets get the bodies fitted before FCS otherwise we will lose to steves rover on track for a second year running...

First up was drilling some 8.5mm holes in the front crossmember. Bolts were provided with the mocal kit as were the mounting plates which i cut down with a dremel and then sanded off the sharp edges. Sanded down the holes and quick spray of black so there is no bare metal to rust.



Both slim line fans fitted and oil cooler all bolted up. The drivers side fan was catching slightly so i had to dremel a bit to try and get the motor to sit deeper in the shroud. that didnt work and a bit of bending made it catch less however it does still catch but hopefully itll just wear and stop eventually. There is a 2 inch gap between cooler and rad but theres no way of having two fans and mounting the two touching.



Broke out the cable ties and secured all the oil cooler pipes. Its fairly tidy now. Tom arrived and got cracking under the car and removed the lamda and fitted the wideband. I took the wiring up and cable tied it to the brake pipes and across the engine bay. Plan is to run it through the grommet around the brake cylinder through to behind the speedo.



Next up was fitting the PAS relocation pipes. the standard high pressure pipe gets cut up in two places and a length of pipe with crush fittings is added between the two. Its actually too long so one of the pipe mounts was removed on the front of the box and the one underneath the front of the box was rotated 180 degrees to make it a perfect fit! Getting a bit tight for changing the filter but will see how difficult that is when the time comes!



Added the PAS fluid inlet to the pump. Standard pipe is cut and a 90 degree bend and down pipe is added. First cut was too high and fluid wasnt running down so chopped off another 2 inches so it falls down to the pump under gravity. We tried to fit a belt to the aux but it was far too short. turned out it was the rallye belt so found the other belt i had kept from the 1.8 which at 1145 was the correct size for this setup.



Next up was throwing the loom on. It was never never good on the 1.8 but the majority of it wasnt too bad and I fitted it in a super tidy way but it will all come out to make a neater one in the future. Below is a pic of the speedo sensor which normally has a 4mm gap where you can push the clip down. because this is down the back of the gearbox and is difficult to remove i took the dremmel to it so you can push the clip down with fingers and not with a screwdriver.



Tom started taking the front end apart and moving everything over to the 1.8 slam panel. The rad clips were broken on the rallye slam panel along with a few of the mounting bolts being sheared.



Fitting the loom where there was a plug which didnt fit which was the gearbox reverse sensor. So on the 1.8 i had to swap the sensor and now ive had to swap it again. Luckily some hero decided to use crimps just in case the loom was used on another box in the future. Cheers past sam!



Next up was sealing up the longmans inlet manifold. On the 1.8 there is no vacuum pump on the head so i had fitted a take off from a single branch of the manifold. Because this is now on a rallye with a vacuum pump ths needed to be sealed up. A shallow headed m8 bolt, nut and some sealant did the trick. Might be able to sort something out with liquid metal in the future but this should be substantial.



All ready for adding the bodies....



Bodies bolted back together with the missing washers and spacers added. Everything done up tight and locktite used so super peace of mind there.



Fitting it was a pain so removed the trumpets and filter back plate. Did the bolts up with a super tool which i was happy with. Filter back plate and 90mm trumpets back on. I forgot to buy new 8mm fuel line so we used the old lines and a few bits i had lying around to do everything up. Need to fit a catch tank as well but just fitted a pipe to take any oil down the back of the engine just to test run it on the drive.



Added the omex and plugged in the last few bits of loom. Boom! Thats how you fit bodies and an after market ecu in two days (18 hours). Big thanks to Tom for coming over and sharing the work. Its been long and tedious battling lots of rusted nuts and bolts but hopefully itll be worth it in the end.