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 604 Posts Member #: 1106 Post Whore Hungerford, Berks |
23rd Jan, 2021 at 06:50:55pm
Thanks Yo-Han
Edited by Graham T on 23rd Jan, 2021. ’77 Clubman build thread
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604 Posts Member #: 1106 Post Whore Hungerford, Berks |
23rd Jan, 2021 at 06:58:12pm
And the final little thing I have been playing with is the headlight bowls.
’77 Clubman build thread
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 (2)[/url] by [url=https://www.flickr.com/photos/150672766@N03/]Rod Sugden[/url], on Fli) 5988 Posts Member #: 2024 Formally Retired Rural Suffolk |
24th Jan, 2021 at 05:10:24pm
I know you love to do things the hard way, but for the headlamp bowl, why not just put a 75mm or 100mm hole saw through the area where the clearance issue is and reverse the cut-out bit so it's concave and weld/epoxy/fiberglass it back in, just in-side out ? Schrödinger's cat - so which one am I ??? |
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604 Posts Member #: 1106 Post Whore Hungerford, Berks |
24th Jan, 2021 at 06:04:30pm
On 24th Jan, 2021 Rod S said:
I know you love to do things the hard way, 
On 24th Jan, 2021 Rod S said:
but for the headlamp bowl, why not just put a 75mm or 100mm hole saw through the area where the clearance issue is and reverse the cut-out bit so it's concave and weld/epoxy/fiberglass it back in, just in-side out ? I had not yet thought about Plan C yet, but I shall adopt this one. 
’77 Clubman build thread
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604 Posts Member #: 1106 Post Whore Hungerford, Berks |
24th Jan, 2021 at 07:02:47pm
I was going to wait another day before trying to release this, but not known for my patience and having got bored this evening, I tried to pry it out with a putty knife between the plaster and fibreglass.
’77 Clubman build thread
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 967 Posts Member #: 3228 Post Whore North of the Netherlands |
24th Jan, 2021 at 09:51:49pm
In awe of your energies and skills
Dazed and Confused.... |
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 2618 Posts Member #: 1246 Post Whore Lowestoft, Suffolk. |
24th Jan, 2021 at 10:10:01pm
The path of least resistance offers least reward.
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 6743 Posts Member #: 828 Post Whore uranus |
25th Jan, 2021 at 10:00:54am
nicely done graham , i often find hot water helps it slip out . Medusa + injection = too much torque for the dyno ..https://youtu.be/qg5o0_tJxYM |
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 428 Posts Member #: 10128 Senior Member Dorset |
25th Jan, 2021 at 10:03:24am
I like your approach, these little details are great. I'm surprised the trim panels didn't offer as much savings, but a nice use of your skills |
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604 Posts Member #: 1106 Post Whore Hungerford, Berks |
25th Jan, 2021 at 10:25:13am
On 25th Jan, 2021 robert said:
nicely done graham , i often find hot water helps it slip out . No soap?? ’77 Clubman build thread
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604 Posts Member #: 1106 Post Whore Hungerford, Berks |
25th Jan, 2021 at 10:26:40am
On 25th Jan, 2021 e5tus said:
I like your approach, these little details are great. I'm surprised the trim panels didn't offer as much savings, but a nice use of your skills If I had not used foam backing, scrim foam and then Leatherette, I'm sure it would have been much lighter. ’77 Clubman build thread
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604 Posts Member #: 1106 Post Whore Hungerford, Berks |
31st Jan, 2021 at 07:20:53pm
Well, my beautifully sculpted Rear parcel shelf was the wrong shape.
On 23rd Jan, 2021 Graham T said:
I also now think I have the rear parcel shelf complete. I say think because I made this: 
But just having looked at replacement parts from mini suppliers, they are straight along the edge that butts up to the lip on the rear bulkhead. I do not have a pattern for this part and I cannot remember how the rear seat fits, so I have to go get that out of the loft and see if I have made yet myself yet more work… The rear seat was about 4mm too high, so I had to peel the leatherette back and cut the parcel shelf down with the jigsaw. The fix never took long at all, but it is still annoying because as said, I did not have a pattern to go to and so I spent 2 nights carefully shaping the front of the parcel shelf to fit the contour of the rear bulkhead. Headlight bowl: Plan C not required. So I layed-up 3 layers of 200gms cloth on the plaster plug, using fast hardener for the epoxy resin this time, just to see if that might help get around the tight radii bridging issues. Cut shaped pieces of peel ply to cover the whole thing without overlapping. Trimmed up the excess cloth and peel ply and spent a fair while trying to consolidate it all and get it into the corners Stuffed it in a vacuum storage bag, sucked all the air out and left it to cure for a couple of days. 
It did not release as easily as I had hoped, but that could be something to do with the layer of polyester resin that I coated the plaster with a couple of days before I did the Carbon fibre lay-up. 
You can see above some nasty white “stuff” on the surface of the part and the fact that the carbon fibre does not have much of a shine. Regardless, that came off with a piece of 220 Grit after I had left the part for another day after release. Most important is the fact that the carbon fibre did actually stay in the tight corners. Next, just to make it all look a little nicer, I brushed over the inside with a very light coat of slightly thickened epoxy resin. 
Then I bonded a 2mm think ring to the back of the flange to give it all some strength. Big thanks to Shane for helping me out with the aluminium ring. I have no face plate for my lathe and thought it better to get the ring made by someone who had the appropriate kit… Finally a coat of thickened Epoxy resin on the outside. 
That so far, is a success. Obviously you can see there are no holes drilled in the flange yet, but I have decided to leave that part until I am ready to install. That way I can rotate the bowl in the frontend to best suit the position of the turbo inlet elbow, rather than guessing at it now. I’ll buy an adjuster kit at some point to get the “nutserts”, screws and spring. I was actually going to make 2 bowls, but I think as I do not need the passenger side modified, I will just use the plastic bowl that I used as the template for this piece. ’77 Clubman build thread
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604 Posts Member #: 1106 Post Whore Hungerford, Berks |
28th Feb, 2021 at 06:36:13pm
Wow a whole month and no progress report…
’77 Clubman build thread
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604 Posts Member #: 1106 Post Whore Hungerford, Berks |
28th Feb, 2021 at 06:41:14pm
This is the mounting panel for the ECU fuses and Relays.
Edited by Graham T on 28th Feb, 2021. ’77 Clubman build thread
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428 Posts Member #: 10128 Senior Member Dorset |
1st Mar, 2021 at 10:47:23am
Not sure how much strength the bulkhead plate provides, I got rid of mine and boxed it out (but i needed the space engine side). But a flat plate with some bead rolling for reinforcement should be ok.
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604 Posts Member #: 1106 Post Whore Hungerford, Berks |
2nd Mar, 2021 at 04:04:19pm
On 1st Mar, 2021 e5tus said:
Not sure how much strength the bulkhead plate provides, I got rid of mine and boxed it out (but i needed the space engine side). But a flat plate with some bead rolling for reinforcement should be ok. Great progress by the way, coming together nicely. Thanks for the reply. I was thinking that the bulkhead plate is made of thin material, albeit shaped which adds rigidity, but ultimately it is only secured with 4 off set screws which are of small diameter (I suppose the sealant also adds a little strength), but as the edge of the bulkhead plate is rolled outwards, not a lot of the plate actually makes contact with the bulkhead anyway, hence I cannot see it is really adding much strength. So I think an Aluminium plate would be good also... Progress is really not as fast as I would like, but I will soon get a 10 day stint on it, so I hope I can get that roof and gutters sorted! Edited by Graham T on 2nd Mar, 2021. ’77 Clubman build thread
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6743 Posts Member #: 828 Post Whore uranus |
3rd Mar, 2021 at 02:39:28pm
lovely crisp holes on that dash graham ,well done. Medusa + injection = too much torque for the dyno ..https://youtu.be/qg5o0_tJxYM |
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604 Posts Member #: 1106 Post Whore Hungerford, Berks |
1st Apr, 2021 at 05:55:12pm
The dash is now pretty much completed. All switches in, brackets made and bonded on.
Edited by Graham T on 1st Apr, 2021. ’77 Clubman build thread
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 52 Posts Member #: 11964 Advanced Member Lindlar |
2nd Apr, 2021 at 10:51:07am
Nice primer work.
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604 Posts Member #: 1106 Post Whore Hungerford, Berks |
2nd Apr, 2021 at 04:57:31pm
On 2nd Apr, 2021 Ralf said:
Nice primer work. Did you do that yourself in the garage? Yes If so, did you use spray cans or work with the spray gun? With a spray gun. ’77 Clubman build thread
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52 Posts Member #: 11964 Advanced Member Lindlar |
2nd Apr, 2021 at 06:34:35pm
great, thanks. |
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6743 Posts Member #: 828 Post Whore uranus |
3rd Apr, 2021 at 07:50:31pm
ooooohhhh vntastic dyn oh oh ohhohoh fun to come ! Medusa + injection = too much torque for the dyno ..https://youtu.be/qg5o0_tJxYM |
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967 Posts Member #: 3228 Post Whore North of the Netherlands |
4th Apr, 2021 at 07:02:35am
Very tidy work Graham! Dazed and Confused.... |
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604 Posts Member #: 1106 Post Whore Hungerford, Berks |
4th Apr, 2021 at 08:58:41am
On 3rd Apr, 2021 robert said:
ooooohhhh vntastic dyn oh oh ohhohoh fun to come !
Yep, lots of fun to come I think. The plan is that this will not go on until later summer. Hopefully I can get one more Dyno session in with the engine set up as is, then when I start the transfer of the engine to the clubman I have some plans for: changing the turbine exit on the exhaust to create a bigger “expansion chamber”. a small re-design of the new “X8” plenum to straighten up the flow in (ie no elbow after the TB) reworking of the IC pipework Reworking of the compressor inlet side to try to sort out the MAF sensor. So while I am at all of that, why not give a VNT a go… I already have a test mock up of an electronic controller built up to replace the existing actuator with a servo type. The basic code is operational but it was all done without a physical VNT turbo at hand. When I finally got one I was amazed at the limited movement of the control mechanism on the turbo, hence I have a little rework of the code to do to get the resolution I would like. I am surprised at the physical size of the VNT turbo next to the GT17. I did not go for as big a turbo as originally planned/ thought: my goal at this point still remains maximum power for least boost/ revs, so I wanted to see if I can get better spool and higher boost lower down, rather than worrying about overall high end capability. I was originally thinking GT2259V, or even bigger frame, but this is a GT2056V, so the small diameter compressor wheel (compared to the others mentioned) should aid faster spool and it should still have enough capacity for way over my power goals. As things stand at the moment I would still be limited by the injector size, which might give me around 230 – 240 BHP. That might change if I can make the change to the 1000cc/min low-z injectors. Anyhow, something for the future. On 4th Apr, 2021 Yo-Han said:
Very tidy work Graham! Thanks Yo-Han. ’77 Clubman build thread
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6743 Posts Member #: 828 Post Whore uranus |
4th Apr, 2021 at 05:38:33pm
maybe a ratio divider arm for the vnt graham,so ,say 3mm movement of the servo equals 1mm of the vnt arm ? , or just extent the vnt arm ? Edited by robert on 4th Apr, 2021. Medusa + injection = too much torque for the dyno ..https://youtu.be/qg5o0_tJxYM |
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