Bad luck mate, not a bad fail though!
I stuck CV boots over the top of my front shocks to get them through ;)

Cheers John, I ordered a couple when I got back.

Ill screw a piece of neoprene covered wood to the bottom of the head rests to stop them going down too far and the gap between the headrest and the seat back be below 25mm.

Other things can be covered or tightened but my front indicators im not sure on. I may try filing the side ones.

Cheers
Stot

Not bad at all!!

Can you post a pic of how you are going to get around the radius for the top of the front shocks. This is something that I have overlooked as well.

David

Job well done I say....all easy fixes thankfully and at least you know that you will get the back end of the summer to play with it:D

On the shocks it was the very end of the spring that was causing the problem so simply rotating the springs so that the upper chopped end is at the back would solve it. I will put CV boots over them like Skov though, £2.50 each on ebay must be worth it for the peace of mind that I wont need a 3rd test.... :D

I didnt have a cover on the lower balljoint nut with the split pin and they were fine with it because its in the wishbone area.

Cheers
Stot

That's a very good fail.

I used stretch boots all around my suspension - some pics in here - http://www.locostbuilders.co.uk/phot...folder=Pre IVA

Well done. I hope I get as short a fail list. :)

Well done, minor items ;)

TT

Thanks TT. Talking of 'T' I got some cheapish bits to see if this was going to work in the roadster with the MX5 engine.





Its a Garrett/AirResearch TBO339 turbo off a Saab 900 I got for £50, manifold was £110 delivered. Fast spool for a mild turbo to around 150-170hp hopefully.

Looks like it will just about work. :cool:

Cheers
Stot

That 'd be a T25 ....standard on the nissan 200sx...it is possible to get over 200bhp out that Andrew

The old Saab ones are a T3 flange as it goes but the specs are very T25 like. I would have definitely got a 200SX one if the manifold were T25.

At the moment I don't know how good my engine is so Ill probably go for something mild to keep me interested and get a second engine I can rebuild over winter/spring to take up into the 200s.

Cheers
Stot

May I suggest that you get your turbo rebuilt ? Not trying to be a damp squid, but if there is play in the turbo shaft, the impeller may catch the housing, sending fillings into the bores. Engine rebuild time. Also if the seals go, it will drink oil, and smoke like hell.:eek: Just don't want your mood dampened by a turbo failure. Excellent job on the car, well done. :D

Damp squid, lol Don't put it on a pedal stool.

That was the plan. I thought i would buy it dirt cheap to see if it fits, and if it does, rebuild it and I have a genuine Garrett at the price of a Chinese copy.

To be fair there is a little play in it but there is no oil in it and nothing is touching/rubbing. No marks in the compressor housing at all. Thats not to say the seals aren't going but when its got oil in it and the shaft is floating in the bearings the play may be negligible.

I'm going to fit a Golf TDI intercooler into the nose cone so if the turbo ever does crap out nothing should make it into the engine.

Cheers
Stot

When I rebuilt mine there was still a little play in the shaft and that was with new bearings so you are correct Andrew there indeed does need to be some play for the shaft to 'float'..... no play would soon lead to failure as the metals expanded due to heat.

All turbos have play in the shaft I'm sure on the web there is tolerances somewhere it allows for heat expansion but I go by if it's not touching the sides it's fine to wind up!!

Well back to the IVA stuff. I got a lot off the list today.

One of the things I hadn't fastened properly was the AFM and air filter so I made up some brackets for it.




Not an ideal place I know but it will do.

Also my shock tops. As you can see below the way the spring end was was causing trouble. I turned the spring and put a single piece of CV boot corrugation on the top of it. The rest of the spring is fine so that should do it.

I also had a length of wires going to the gearbox that wasn't secured at 300mm. I drilled a small hole through the rib on top and secured it to that.



My headlights had some radius issues too. I added some piping but I had to add an extra large washer to give the piping something to grip to. I made a washer that could slide under rather than de-wire everything.

Also made some addons to my headrest. I started by making a copy of the tool they used to measure.



I got the point of the 'arbitrary' 136x53mm block when they were using this. The position is roughly where the base of your spine is when you are seated.

Standard position was just a little low,



so I wrapped a piece of wood in foam and leather and screwed it on to the bottom of the headrest. Added some fuel hose as bumpers to stop it being able to click in position too low and voila, higher than 700mm and a gap no larger than 25mm.




I also filed my side indicators and they are now greater than 2.5mm radius. Probably going to have to swap the front indicators to something else though unless I can find some 3/4 round edge rubber or something.

edit: Im going to try some of this heavy duty heat shrink tubing. One or two layers should bring the radius at the front edge of the unit up to over 2.5mm.

Cheers
Stot

Done my list now except the headlight aim and the front indicators.

Covered the exhaust clamp with heat wrap.



and tightened the handbrake cables on the calipers.



Course originally I checked these when the handbrake was on so the felt tight, with the hand brake off though it was obvious they were loose.

Still got next weekend to come up with some ideas for the indicators if the shrink wrap doesn't work. Headlight aim we can do at the retest.

Cheers
Stot

Indicators possible Plan B. I thought the washer idea from the headlights might work here.





I will probably have to glue this on so plan C is a hybrid of one of these slightly smaller with shrink wrap holding it in place.

Cheers
Stot

Ok so Plan A worked out perfectly.






When shrunk this is over 1mm thick so the radius is more like 3.5mm now.

Now that I have the heat shrink I think it would be/have been a good solution to the shock tops and even the headlight brackets too!

Cheers
Stot

Clever that, I didn't know you could get heat shrink that big. :eek: Where did you get your track rod end covers from? Do you have a link?

Chris,

I got mine from furore. They were fairly cheap but I'm you you can buy them at screwfix as they are just electrical glands.

With the agm bodywork the front lower wishbones adjuster tube sticks out. I have bought 4 x 25mm silicone black end caps from ash hoses and they cover them nicely.

David

Yep I got them through Fururueuoore too but on ebay.

Just snip the tip off and they slide on nicely. The ones from Screw Fix come with all the gubbins you dont need.

Cheers
Stot

Almost looks like they came that way. :cool:

Thats the IVA failure list done except the headlight aim, roll on Wednesday! :D :D

Cheers
Stot

Thanks for that I will purchase some forthwith... They look better than before Andrew.:cool:

I got my TDI intercooler in the post today for my post IVA project.



Its not huge, 8" x 7" x 3.5" core but should fit nicely in the nose cone and be fine for my purposes. It even came with a combined 3bar MAP and IAT sensor I can mount onto my intake plenum.




All for £18, cant grumble.

Cheers
Stot

Well that all worked.



Whoop! :cool:

Cheers
Stot

Woo hoo, nice one mate!

Congratulations Stot! You car sets a very high standard, I always found it stunning!
Well done!
Now, you can enjoy the roads in summer time :)

Many many congrats Andy.... even though its a re test I'll hazard a guess and say your smile was beyond ear to ear (well it was with me) hurry up and get your reg stuff in to enjoy a late summer blast

Congratulations on a pass well deserved

Arfon

Thanks guys. Yes it was a nice feeling to get the piece of paper.

Now the registration process to battle on with. I think I'm all set with that except I didnt have insurance up to now and you need that to register and get your first tax disc so I have got a year with A-Plan nice and cheap at £148 4000miles/yr which should be plenty so paperwork should be going to the DVLA tomorrow.

They even confirmed that they can put my private plate directly on the car (assuming it should get a donor related plate anyway) so I dont need to wait for a DVLA assigned one and then wait for it to be transfed. Bonus!

Ill have a trailer for sale as soon as the registration is done too. :P

Cheers
Stot

Congrats Stot, great build :)

Congrats, well done.

Congratulations. Must be great to have the pass now.:)

Well done on the pass. £148 is cheap too for ins.
Keep chasing the dvla after working day 10.

Thank you thank you.

I should stop really but my post IVA list now includes,

Windscreen and wipers
Plumb in a Microsquirt ECU
Re-loom
Turbo
Clam shell wings
Spare wheel carrier.

I'm most looking forward to Microsquirt and re-loom at the moment. :eek:

Cheers
Stot

You're a sick man!