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Re: Cosworth YB Turbo Into Elan

PostPosted: Thu Feb 09, 2017 10:15 am
by stevebroad
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Ah, that's a bit better.

Re: Cosworth YB Turbo Into Elan

PostPosted: Thu Feb 09, 2017 7:44 pm
by mbell
stevebroad wrote:Ah, that's a bit better.

Yup and if you click you can view nice large version. Not sure what you were doing but seem to have sorted it now :)

Re: Cosworth YB Turbo Into Elan

PostPosted: Thu Feb 09, 2017 11:06 pm
by stevebroad
Got stuck in to making the the pedal box recess box, if that makes any sense? In order to lower the pedal box by 60mm I needed to cut a hole in my recently made and fitted carbon floor :-( and fit a box to take the pedal assembly.

Hole(s) cut and a rough tryout indicates that the new box has given me enough room to operate the car.

Next job was to make 280 x 280 x 60mm open topped box with a lip. Cut up a piece of 50mm thick styrofoam and added 2 layers of 5mm dense foam sheet. Stuck this to a glass base and added the vacuum bagging materials. All went well for a few minutes until I realised that no resin was coming though to the breather cloth. I then realised that I had used the wrong bloody release film. I used the type for prepreg which has no holes in it. The stuff for wet vacuum bagging is covered in small holes that let the excess resin flow into the breather cloth.

Stopped the vacuum pump and unpealed the vacuum bag from the double sided tape, changed the release film and it was at this point that it went pear shaped. I managed to get resin on the vacuum bag and this transferred to the double sided tape. This stopped the bag sticking to the tape so I couldn't get a vacuum.

If further proof was neded that gaffer tape can fix anything, here we are. Fortunately I have a couple of 15" wide rolls of the magic stuff and after a few minutes I had enough of a seal to create a decent vacuum. Only downside is that I will have to leave the pump running over night as the seal isn't perfect. I can't hear any leaks but there is at least one.

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Re: Cosworth YB Turbo Into Elan

PostPosted: Sun Feb 12, 2017 10:58 am
by stevebroad
Things don't always go to plan. I was modifying the next two master cylinder reservoirs yesterday. First one went fine and so did the second one until I relaised that I had made it slightly too tall. So back on to the lathe it went. I had to hold it internally in order not to risk damage to the thread but this hadn't been a problem, I just had to be circumspect and gentle with my tool feed. This time, however, I must have got just a little bit too ambitious and twang! it flew out of the jaws and ended up like this. Oh, well, not the end of the world :-)

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Re: Cosworth YB Turbo Into Elan

PostPosted: Sun Feb 12, 2017 2:56 pm
by stevebroad
Unwrapped the pedal box lowering box, came out OK (the mark in the centre was caused by the vacuum fitting. I usually locate it away from the item but I thought that I had placed enough breather material under it to stop this. Oh well, it is under the car and it isn't a trailer queen).

Fits in the floor...just. However, it confirms my fears that I can't site the reserviors directly on to the master cylinders.

Rethink mode......... Ah, right, how about just in front of the seat? Leaves room for feet to get in and out and easy access to them. I will investigate this further.

I will raise the footwell roof a little bit over the clutch pedal.

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Re: Cosworth YB Turbo Into Elan

PostPosted: Sat May 06, 2017 12:01 pm
by stevebroad
I have just realised that it has been a while since my last progress update, so apologies to both of my readers :-)

The Reservoir Saga......The options of mounting them to the master cylinders or in front of the seat turned out to be no good due to space restrictions and fluid flow back. I didn't want them in the hot engine bay so, after a bit of head scratching, I settled on locating them behind the dash. Access would be an issue so I have mounted them on a door :-)

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Tried using rubber pipe to connect reserviors to the cylinders but wasn't happy so went to 8mm copper. Had to make fittings to attach pipes to banjos. Master cyliinders now also attached to the rest of the system.

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Steering column... This had to be modified as I had changed the steering wheel angle so had to fit a knuckle. Whilst thinking about this decided to replace whole column with a titanium version, apart from the splines which caused unexpected problems. When it came to weld on the splines we discovered that mere mortals can't weld steel to titanium as the welds crack.

Ooops, game stopper for a while. However, on discussing the problem with Permabond they recommended a glue that would do the job. But they won't be driving the car so I decided to sleeve and pin as well. As I have used tube rather than solid bar the weight has reduced from 1450gms to just under 700gms.

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Re: Cosworth YB Turbo Into Elan

PostPosted: Sat May 06, 2017 2:50 pm
by bigvalvehead
Nice work Steve

Re: Cosworth YB Turbo Into Elan

PostPosted: Sat May 06, 2017 8:52 pm
by stevebroad
bigvalvehead wrote:Nice work Steve

Thanks Dave. Little by little :-)

Re: Cosworth YB Turbo Into Elan

PostPosted: Fri May 26, 2017 2:47 pm
by stevebroad
A few more things done.

Coil pack, oil pressure, fuel pressure and 4 Bar MAP support bracket made.

Made aluminium pattern which I laid the prepreg carbon into:

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First fit. Painted black to hide carbon weave:

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Also a boost controller bracket out of a piece of scrap carbon sheet:

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Re: Cosworth YB Turbo Into Elan

PostPosted: Fri May 26, 2017 3:37 pm
by roblotus79
You had me at 4 Bar MAP :)

Re: Cosworth YB Turbo Into Elan

PostPosted: Fri May 26, 2017 9:03 pm
by stevebroad
roblotus79 wrote:You had me at 4 Bar MAP :)

Sorry, 4 bar absolute :-)

Re: Cosworth YB Turbo Into Elan

PostPosted: Fri May 26, 2017 10:49 pm
by elanfan1
Measure that piece of string multiply by 4 and guesstimate when the car will be finished (if it ever is and by that I mean you'll probably be tweektng things forever)?


Don't understand much of it but you sure are determined. Impressed!

Re: Cosworth YB Turbo Into Elan

PostPosted: Sat May 27, 2017 10:54 am
by Certified Lotus
Steve, I continue to be astounded with the fact that every single thing your doing in building this car requires a unique and "never been done before" approach. Even more amazing is that you always find solutions!

Keep up the great work you are doing, your an inspiration to all of us that just need motivation to restore our cars with a shop manual :P

Re: Cosworth YB Turbo Into Elan

PostPosted: Sun May 28, 2017 10:57 pm
by stevebroad
Starting on the engine plumbing; oil, fuel and boost pressure connections.

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Re: Cosworth YB Turbo Into Elan

PostPosted: Wed May 31, 2017 9:57 pm
by stevebroad
Little by little. Clutch pipes finally finished. Boost contoller tubes cut and first fit.

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