Cosworth YB Turbo Into Elan

[Chancer]

Steve.

Look at bighead bonding fasteners next time.

Being a functional rather than decorative fastener they wont look as slick as your creations though!

[stevebroad]

Steve.

Look at bighead bonding fasteners next time.

Being a functional rather than decorative fastener they wont look as slick as your creations though!

I have used those on the carbon seat I made. However, they aren't available in the exact size I require and, as they are made of steel, are very heavy Also, with Bigheads being around ?2.50 each, I saved myself ?75 using aluminium I already have. Time spent making them isn't an issue

[Spyder fan]

Had my first walk around the car since getting it back from having the wiring completed, making a list of jobs still to do. Probably missed a lot but this is something to work on

Secure intercooler
Modify radiator brackets to allow repositioning.
Fit air filter box
Finish air intake pipework
Fit header tank pipes
Get header tank filler cap
New pipe from overflow bottle to header tank.
Make new exhaust heat shields in CF
Fit wiper motor (either fix original or replace)
Finish front bulkhead and add heat shield material
Finish engine bay bodywork
Secure and adjust steering rack/rod ends for bump steer
Finish front clip
Fit injector rail and injectors
Connect up loom. Adjust position and wire lengths where necessary
Repostion ECU support bracket
Fit dash cover and cut hole for access
Fit screen wash jets and piping
Weld in additional roll cage tubing behind seats
Fit roll cage cushioning
Fit interior panels
Make doors and glass
Secure glove box door
Secure switch panel
Secure centre console and tidy up edges
Make front screen
Make and fit new roof and rear screen
Sort out fire supression system
Fit EGT and Lamda sensors
Fit oil filler cap
Get and fit plug leads
Fit plugs
Secure fuel tank and nitrous bottle
Get new electric bottle opener (or fix old one)
Fit fuel filler cap
Fit rear lamps
Finish droop limiters
Tighten ALL nuts and bolts, marking as I go.
Door locks and hinges
Get seat belts and fit
Parachute bracket
Under floor trays, side splitters and strakes
Rear view mirror
Fit and wire up remote tyre temp sensors
Change front springs
Make new radiator bottom hose
Fit hose clips to header tank hoses and secure
Fit exhaust box and cover
Fit heat shield material behind exhaust box
Fit boot
Bond in floors
Bolt on exhaust manifold and turbo
Fit turbo support strut
Reposition alternator/battery cable
Repostion loom through bulkhead and fit grommets/covers
Final fit of loom, adjusting wire lengths where necessary
Connect battery
Sort out wheels and tyres

Talk about " Note to Self"....... I am taking inspiration from your thread for my next project, it won't be on the same scale but it reinforces my normal "don't tell me I can't do that" philosophy.

[stevebroad]

Had my first walk around the car since getting it back from having the wiring completed, making a list of jobs still to do. Probably missed a lot but this is something to work on

Secure intercooler
Modify radiator brackets to allow repositioning.
Fit air filter box
Finish air intake pipework
Fit header tank pipes
Get header tank filler cap
New pipe from overflow bottle to header tank.
etc

Talk about " Note to Self"....... I am taking inspiration from your thread for my next project, it won't be on the same scale but it reinforces my normal "don't tell me I can't do that" philosophy.

No such thing as can't, well, not many. However, there is no such thing as a problem in my lexicon, only challenges.

Easy stuff is boring, difficult stuff is fun. Also, doing something that appears to have not been done before gives a real buzz AND I love making things, always have done.

[stevebroad]

Front and central aero panels in position. Next task is to fit the fasteners. After that I need to add some additional sections to cover the holes between the front tyres and existing floor.

[Chancer]

That should be a "Spot the Elan" photo contest

[stevebroad]

That should be a "Spot the Elan" photo contest

[rgh0]

Hi Steve

Time to get yourself a MaxJax or similar to get the car up in the air with all the under body detail work your doing rather than blocks of wood.

Also makes it much easier when you need to do a full check of under body, suspension and drive line before the next race.

cheers
Rohan

[stevebroad]

Hi Steve

Time to get yourself a MaxJax or similar to get the car up in the air with all the under body detail work your doing rather than blocks of wood.

Also makes it much easier when you need to do a full check of under body, suspension and drive line before the next race.

cheers
Rohan

Hi Rohan

I am only using the wooden blocks so I can install the aero panels. The car normally sits on this lift, which raises the car up to around a metre, which is perfect for working on it.

As there is nothing under the car that needs access (apart from the gearbox mount) it works perfectly. The 2 post lift restricts access to the car as the posts are usually in the way of the doors Also, my garage space is a little narrow so it would greatly restrict movement. However, my new garage, when built, will be a little bigger so I am thinking of getting a 2-post lift for other vehicles.

Regards
Steve

[stevebroad]

You spend 6 hours working on your car but it looks no different from when you started. Spent the day securing the underfloor aero panels. This entailed drilling and gluing in the top hat nuts I made a few days ago.

Still a lot of work to do to finish the panels and the remaining existing floor plus the addition of strakes to the panels as well as the side splitters. The final shape around the tyres will be done once the new wheels and tyres are fitted.

Also secured the front wheel speed sensor wires by passing them through the top wishbones. Added a couple of tabs to assist in locating the front clip. Adjusted the front aero panel straps so it fitted snugly to the splitter.

[stevebroad]

Looking for more ways to reduce weight, I started to attack the locks. Doing away with the door handles and lightening or replacing what remains with carbon fibre. Replaced latch cover with a CF version and also the rods connecting interior door opening handle and the latch.

Made a prototype door button. Need to fit to car along with the latch to finalise design.

This work will remove over 2Kg. Also replacing OEM wiper motor with the rear screen motor from a Fiat Punto. Weighs 1.5kg less. Also converting to single wiper. Just need to reduce swept angle from 180 to 110 degrees.

[661]

Interesting.
I'm converting my elan to using a Porsche 964 wiper system, again needing to reduce the sweep from 140 degrees to about 115. I'll keep both wipers.
If you've not seen the tinkering on the wiper system on 'Project Binky', it's worth a look, I think it was episode 18.

[stevebroad]

Yeah, seen them all

Over engineered as usual on this project. I am simply going to move the rod connected to the wiper gear a little closer to the centre, thereby reducing the rods movement. Using CAD I reckon about 6mm should do it.

[661]

Yeah, seen them all

Over engineered as usual on this project. I am simply going to move the rod connected to the wiper gear a little closer to the centre, thereby reducing the rods movement. Using CAD I reckon about 6mm should do it.

The Pork system needed the actuator rod on the motor reducing from 24.5mm to 19.5mm using the rule of thumb.
The spindles also needed separating by 85mm. All good fun.

[Certified Lotus]

Steve, I like your garage plan. Nicely laid out. Once it?s done you will have plenty of room for your next project or at least the constant fiddling needed on your current one.