bonkas

My issue is I am retrofitting a newer 90s alternator and only using the sense and bulb wires, auto electrician said voltage would be high as it is not computer controlled. Not sure there is any way around this without putting old anemic one back in... When I tested the sense wire it had exact same voltage as at battery, will need to check again.

Tad bit longer video with a bit of a rev up after getting alternator working. Alternator is pumping out a massive 15v so will probably cook this battery is short order, anyone have hookups on calcium batteries? It is my thinking they require higher charge voltage and might be a good fit, otherwise auto electrician said he may be able to bring voltage down.

I am wondering if anyone in the area has a carb balancing tool sitting in thier shed I could borrow for a few days. Need to balance some twin side draft weber. Thanks in advance

@ToMitz Despite a massive water leak from the pipe that runs into the back of the water pump... The O-Ring seal it came with from factory appears to be too small. But I succeeded in this: Bit of carb tuning and watching oil pressure and she idles sweet as. The oil pressure gauge in the dash is really jumpy and inaccurate but I have confirmed with an external oil pressure gauge I am getting 60PSI of pressure so I am ignoring that for now.

Im not too worried tbh but I am not sure if my modifications will require certification, if it does I will need to put in a catch can by the sound of it. For the time being I will just add a smal filter to the breather pipe while I get the engine running. You guys are a huuge help.

So in regards to cert - I can just plumb them both into the air filter and be done with it? The catch cans I see for sale have a filter on top and a catch can to catch any fluids but Im not sure how this is any different to putting a filter on the breather on the rocker cover? Something like this im talking about: https://www.trademe.co.nz/motors/car-parts-accessories/performance/turbos/listing-1965388838.htm?rsqid=1121f181243042b59e10c83a27c359b3

I seem to remember a thread on here a long time ago which I can no longer find discussing the rules on venting crankcase emissions. I have gone to dual sidedraft carbs and wondering if I can simply block off the front PCV valve and put a filter on the rear rocker cover vent? The engine is newly built from the ground up so I am hoping for very minimal blowby etc. This is in an early 4g63: PCV bottom left, plain rocker cover vent right hand side center (rear center of rocker cover)

@fletchHaha he seemed to have changed his mind overnight, I have tee'd off the water to the heater so it flows back to the return when the heater is closed. Water is all plumbed up now! I got to get another fuel pump (which is on the way) as the old one had no flares on the fittings and the fuel hose slides off to easily.

Today was a big win! Intake is FINISHED!, machined some material out to space out the distributor the correct distance same as stock manifold. Got Alternator mounted, had to modify the bracket as it was too close to the coolant hose and wouldn't let a hose clamp slip on. This is because I am using an alternator from a new model and had to make spacers to allow it to fit and machined the old pulley to fit the new alternator, because of this it sits in slightly different spot to the old one. Got the Radiator and fan mounted for the last time, installed the bottom hose, top hose I will need to modify to allow the inline temperate sensor adapter - This will control my radiator fan. Installed the temp sender for the dash gauge into the manifold under the thermostat, I have read this isn't really the best place for it but unfortunately there was no room anywhere else. Got the heater hoses all plumbed up using various heater hoses from mitsi vans, commodores and falcons. The Fuel pump is mounted... But I will need to replace this with another unit as the hose fittings don't have any barbs on the end and I am afraid I might get a hose pop off. Finished the throttle linkages, just need a bit of adjustment and mount the bracket that hold the cable somewhere. Next on the list: Find another low pressure pump Mount Fuel Regulator Find some air filters that will let me use the air trumpets Mount fuse box Mount vacuum pump Wire up Fuel Pump, Radiator and Vacuum Pump Install distributor, plugs and leads for the final time If anyone can help with the above especially the fuel pump, find a quiet vacuum pump and if your in the Waikato and can offer a hand with the wiring!

@Roman @fletch Yeah, I have been trying to make this happen to get the water return line but dad isnt having it, thinks it's not needed. He's the kinda guy where his word is law and im having trouble changing his mind. I think I will plumb the heater line into a tee so it splits off to the return also. @MaxPower thanks for the offier, we will be building a 2.25" system from scratch.

Well I finally have done enough for another update.. Have the headers completed, painted and fitted to the car. The fun of building the rest of the exhaust has now started the planning stages! The Intake is finished, I decided to block off one of the returns and just plumb up the heater, I didnt think there was a need for a water return at the rear of the engine going back to the water pump unless it is there to aid circulation when thermostat is closed? oh well, if this becomes an issue I can tap a fitting in at a later stage I guess. Have started on the throttle linkage, should have that knocked up this week.

Dad slaved away all day yesterday for me.. I now have this: Gotta weld in ports for vacuum lines, fabricate thermostat and heater piping next... Slowly coming together.

Bit more progress today. Got some misc parts cleaned up and painted. Started building and mocking up the intake manifold, all looks good until mocked up against the engine.. Someone has put a damn Distributor in the way! also the carbs are very wide and ports on head are very narrow and close together. I think I will need to shave off the linkage and bosy of one of the carbs to make enough clearance to squeeze a throttle linkage in and clear the distributor cap. Sorry I have no pics of this.

Thanks guys, appreciated!

Is there anywhere in NZ where I could buy various stud sizes from? I need to start mocking up intake and exhaust manifolds and want to go to studs rather than a stud/bolt combo, having thicker than usual flanges im not sure on the length I need. How much thread should be inserted into the head, 20mm? - I dont have the original studs/bolts so not sure how deep they were. Can M8 studs in various lengths be bought online?

Turns out I should have measured more thoroughly... The fan I picked is too think by about 10mm and will not clear the water pump and pulley on the front of the motor. Hopefully I have a fan coming which is 15-20mm thinner which I should be able to modify to fit the same as the old so I don't have to muck around with modifying or making a new shroud.

Thanks to @Geophy I have my radiator pretty much sorted, just have to remove hunks of metal left in there from the radiator guy, I have got some out by shaking it, hoping I can get the rest out without cutting it open... Grrr.

Hey Guys - I am hoping there is a OS'er out there keen on some cash to help me out in fabricating a shroud for my Radiator and Electric Fan. Wanting to make a simple shroud with aluminium sheet that bolts onto the original mounts to fit the fan - Going from mechanical to electric fan. I dont have the skills or tools/workspace required to do this. Hoping to help out/learn along with way if any OS GC is keen.

Big day today. Feels like ive got over a huge hurdle and reached a milestone. Car up on hoist: It now has a heart.... not beating yet.. Thanks @ToMitz for the cam pulley, looks really sweet actually, much better than the stock pressed steel thing. Have new engine mounts, new gearbox mount, master cylinder has started leaking like a fountain for some reason as I have not touched it, will need a new one of those too... Next up is to bolt up odds and ends like alternator, radiator, put interior back together and start building the manifold with the help of my dad.

Long time since I had an update on this... Gearbox is now mated to the engine, after finding out the Donor EX had a sigma gearbox and 1200 driveshaft and unknown diff, I was under the impression from the seller these were all stock... I found this out when mating the gearbox was too easy! New clutch disk to suite the 1600 box and all is happy again - I now have the clutch parts required to mate the sigma box up after a quick inspection and possibly rebuild as it is in unknown condition and the donor car was in very rough shape, Interesting they didnt modify the shifter or floor at all to make this gearbox fit as I thought that was required.. maybe on in the LA LB lancers? First time fitting a flywheel, clutch, pressure plate etc so it took a few goes before having everything correct but it should all be torqued to spec. I did find after mounting the gearbox there are some bolts which are missing, this is strange as I used all the bolts I had kept from the 1600cc motor, I can only think there may have been exhaust mounts or something that bolted here so I will have these bolts they are just in a different hiding place. some pics for thread:

Have had my radiator re-cored. Have gone from 70 tubes to 120 and the tube size has gone from 10mm to 12.4mm which should make a big difference. Also have The flange for the carb side done.. still trying to work out how I am going to build this manifold.. the carbs are 40mm and needs to taper down to 38-39mm, I am thinking of just getting some thick walled aluminium and machining it out on a taper to acheive this, or get some thin walled tube and cut a V in it and re-weld to create the taper - What are your thoughts? how have you guys done it in the past?

Last night efforts! Bruised, covered in gearbox oil and dirty engine oil. Just left with a load of bolts and brackets which I have no idea where they came from haha

Got it sorted. This is how it turned out:

Got the flange cut, realy nice job they have done cutting it out, jst need to port match the intake holes and we are good to go, any got any tips in doing this?

@bigfoot @rich1179 I think I have found them inside a box of parts for another vehicle!