Truenotch

Truenotch's BEAMS AE86 racecar

140 posts in this topic

Engine mounts mostly welded on, need to pull the engine to get right around. Gearbox mount will be sorted on Thursday night then it's time to get a driveshaft made and take it home for front tub work and some firewall cutting.

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ECU is being ordered today and engine parts will be back from balancing this weekend, so it's almost engine building time! Need to decide whether I'm taking some meat off the head to raise the compression to 12:1 or just being happy with 11.5 for now...

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Started on Tub #1 tonight:

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Clearance galore:

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Now I need to make a patch for the front and cut out a nice shape for the inside of the guard then get it on a hoist with the guards off to weld the inside of all the lap joins.

If anyone's planning on doing tubs, I recommend this method as a quick and easy option. So far it has only been a few hours work with some cardboard, an angle grinder and a ruler.

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Got mail today, this shot from February was part of it:

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Perfect clearance in the front! Need an extra 25mm of offset in the back...

Edit: another - last corner before it died in June

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Things are moving forwards!

A bit more choppy, weldy and tubbed-ness than last time and we've sorted out the shifter position/hole. Driveshaft length has been measured so it's time to rip the block out and start building some engine :o . Yay!

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Still umming and ahh-ing about whether we should skim .5mm off the block to bring the compression up to 12:1 ... Surely it can't be a bad move?

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Back on the ground!

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Engine bay looks like this - ready to be cleaned and painted.

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Clearance!

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Tunnel work + shifter box

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Sweet! Fab work is mostly out of the way now. All I need to do is weld the rest of the engine mounts to the cross member before waterblasting and painting. Woohoo! Also have everything needed to build the engine now, so that will begin ASAP so we can throw it all in the hole, add a computer, tune it and go racing...

Can't wait 8)

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I've had way too much on lately but am starting to get into this again.

Painted the cam cover today with wrinkly stuff and it came up well! Recommend running a heat gun over the painted surface as it dries for the best wrinkly results.

Mocked it all up with Roman's 110mm trumpets (cheers for the borrow) and made rude faces in the garage.

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Pulled apart my oil pump to give it a check and clean - all appears to be good so I'll slap that back together in the morning and fit the oil pump, water pump, idlers, cam gears, belt etc before lunchtime and work on modifying the sump to minimize oil surge. I'd like to have the engine back together by the weekend so we can throw it in the hole!!

I've also been working on a front splitter - the lip doesn't sit low enough, so for now I've added a rubber lip ext3nd0r from a Honda Integra / quint. The undertray is 4mm ply and will get a couple of ali u-channel gussets to stiffen it up. Plywood rules because it's lightweight, easy to work and is compatible with rivets or screws:

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The heat gun will come back out to try and straighten the lip, but this setup is only temporary for testing. I'll eventually cut the bumper and lower the main lip / splitter so it sits level instead of leaning back.

Oh, and...

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8)

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Few anxious moments getting it going but all went well in the end.

HUUGE big ups to John / CXGPWR and Bennis for wiring the G4 in as a team and doing all the electrical things that leave me clueless.

All looking good for the dyno in the next week or so... I need a new radiator ( mine is poked) but apart from that there doesn't appear to be much holding it back now

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Front fell off:

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Have ordered a new radiator and bought what I need to make a new removable slam panel. Yay for cold air and brand new stuff.

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Some progress:

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Bolted on a few panels to make it look like a cars again:

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Next up is making ducting around the whole shebang and maybe adding a divider between the two areas - not sure whether that will help anything yet though:

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Yay progress. viewtopic.php?f=18&t=14421&start=500

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Have carried on working on the cooling and cold air feed. Here's a vague idea of how the inlet will run:

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Front profile - half radiator, half cold air with a divider between:

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Today's effort focused on building the basics of the air box. The base plate is made from 2mm aluminium and seals off around the back of the firewall using a door seal. This plate stays bolted to the engine and the rest of the box will be chassis mounted with door seals where they join up (if that makes any sense). The top will stay open all the way along and seal onto the bonnet (door seals on the box and on the bonnet to make a good seal).

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Door seal + firewall:

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Big hole:

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And finally with trumpets:

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Now to figure out how to join it all up!

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A wee list to work through:

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And more progress on the box:

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We also made an ugly feed prototype / filterer housing. I's been butchered multiple times to make it point in the right direction, but goes where I want it to and will be a good template for making a decent one after the next run on the dyno.

Gonna go to para rubber tomorrow and see if there's anything better than door seals to use for the top of the box - need something that's easier to work!

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Back on the ground!

Still need to finish bits on the air box and get back on the dyno in the next couple of weeks, but am going to shake it down tomorrow 8) .

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Hope nothing falls off!

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Shakedown complete, here's some proof:

The tune isn't finished yet, so I was only revving it to 6500rpm to be safe - goes pretty well up to that point, but wants the extra revs to really come alive! I was running out of revs in 6th on both straights, so will definitely need the big revs once it's on a track with grip.

Times were similar to the old setup already - I was doing 1:22's in the dry and had a piss all grip, so things are looking good.

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