a few pics of last night and today's progress got the front cross finished, mod'd the pedal box to fit the smaller hole and fitted the s2000 clutch master, shortened and re clipped the rear break pipe, made a new pedal box side cover, painted the bits were i have had to grind and weld etc etc

front cross


pedal box, tunnel etc


3" prop shaft


tilly

Its In Part 1
 

Hi all got the engine in properly tonight, very pleased.
couple of pictures with descriptions underneath


just a basic overview of the install


Oil filter relocation plate, i had to modify this slightly sine it was designed to retain the OEM cooler so i had to shorten the stud that filter would originally have screwed onto, it was quite involved since the treads did not run all the way down so to shorten it i had to basically remove a section from the middle of the stud and re weld it together, did it all in the lathe with the TIG the result was very pleasing.


Clutch slave cylinder with a little banjo fitting that i made an adapter for to go onto a standard M10x1 pipe fitting


Propshaft installed in the tunnel, i must remember to torque the bolts before the test drive they are only finger tight at the moment.

Its In Part 2
 

Hot side of the engine. The manifold will run very close to the chassis rail, it will come out of the port and have to kick up slightly to clear the chassis rail, not a big deal really but it will require some heat management in the surrounding area



New radiator, alloy race rad from a honda civic del sol, fits perfectly in the space and even has the same size hose's, i also have a new slim fan (not shown)



And finally my attempt at an artistic photo, doesn't show much but i think it looks cool.

Edit: tell a lie it shoes ground clearance quite well

tilly

Cool work
 

You are certainly cracking on with that job Tilly :)

Very much looking forward to seeing the completed job & the report of your first test drive with the new engine fitted :) :cool:

One thing for sure, going to be a whole bundle of full on mayhem :D

very nice, going to have a bit of a kick that one! wipe clean seats anyone?

JakeH

update
 

hi all
quick update, quite an exciting one really since i fired up the engine for the first time tonight, it went second attempt, would have gone first attempt if only i had turned on the battery isolation switch first
anyways here are a couple of pictures





still got some wiring to do as you can see, also need to connect a throtle cable, make a new exhaust, bonnet, dash, tunnel cover etc
might get a new battery too since the one i have is a little large

update:

been making the exhaust this weekend, been lucky in that i had got a bit of extra tube and a couple of bends left over from the last one and have been able to use some bits from the old manifold. unfortunatly ran out of gas so i will have to get a new bottle this week.

will try and get a photo up later

tilly

Great stuff Tilley :) :cool:

I guess it will not be too much longer before the Roadster is back on the road :)

that seems to have just fallen into the hole left by the previous engine !
look foward to seeing some more progress

i am very jelous !

thanks it is a bit of a squease in a couple of places but all in all fits very well and should give good weight distribution.

tilly

Warning what you are about to see may be considered by some to be an explicit image.












:D :D

:eek: :D automotive porn indeed :cool: :cool:

Stunning work Tilly, can,t wait to see the start up video .

cheers
andy

thanks andy, it has been running a couple of times very briefly already, i will try and get a video of it when the exhaust is on and i drive it out of the garage or something.

tilly

WOW, nice work. Do you make manifolds for a living? The reason i ask is that I'll be wanting a new one pretty soon.

no i dont make them professionally, i would make one for someone else but it would be very expensive and i would need the car to be at my workshop since it would be a one off made to fit manifold.

thanks for the complements :D

tilly

Thats a work of art ..do you buy the prefab bends or do you have a bending machine ? where did you get the 4 -1 collector from ?

thanks, i do use pre made bends then cut them to what angle i require. wish i did have a bender, i might make one some day as i really fancy one. the collector is actualy a 4-2-1 made from 3 pre made 2 into 1 reducers, i think i got them from a company called jetex, they are ok but are mig welded so dont look quite as nice but they are quite a good price
the manifold consists of 1&3/4" primary's, 2" seconds and a 2&1/2 tail

tilly

http://www.clockwisemotion.co.uk/index/cars.html

Some interesting reading on here re exhaust manifolds for the Honda in a Caterham.

Lots of lovely tuning goodies too.

thanks for that, it is very interesting indeed, shame most of there parts are for the K20 engine

tilly

Do you fancy putting together the exhaust for the Single Seater Tilly? It's going to be very tight going round each side of the engine into twin pipes leading out the rear of the car......;) Worth a try

Looking really good though.....AndyH

Sweeeeeet.... Be ready in time for the snow :)

TT

Thats it I gotta come see the single seater hope you there in the next 2 hours

iy, you might be right lol, made a list of jobs to do tonight now am feeling very unmotivated

still plenty of driving days left matie. yesterday was gorgeous weather down my way

hi

very nice install, im looking at fitting a S2000 engine into a kit car as i have a s2000 i am breaking and seems a shame to let the engine and running gear go,

Im mainly interested in your wiring as i was told you would not be able to use a stock ecu and you have done so,

have you just used the stock engine wiring loom and ecu? have you had to by pass any wires/sensors?

thanks rob

I got told the same thing, " oh you wont be able to do that" "thats not possible" etc etc

just got the engine loom, under dash loom ecu, ign barrel and key. chopped out all the redundant wiring (about 90% of it) put in some new fuses and relays for lights, fuel pump etc turned the key, touched the wires together and away she went.

you NEED a copy of the WORKSHOP MANUAL, it has all the wiring diagrams in it, available from the bay for about £4

oh and fit a sump guard, dont ask how i now, it was an expensive and stupid mistake *doh*

dead easy really
any questions just ask

tilly

Well after my expencive mistake ^^^^ lack of sumpo guard ^^^ and a heavy passenger

iv finished rebuilding the S2K engine

Started up second try (battery was a bit flat first time)

Touch wood its ok, only had it running at idle.

still got TONNES of work to do before the shows start
New bonnet, new dash, full cage *maybe* , sump guard, yes definetly a sump guard, blank of the old exhaust outlet, repair a few scratches and dents, and give it a dam good wash and wax

tilly

What happened to the engine?:eek:

I took a rarther hefty friend out and put a hole in the sump starved the cam shafts of oil, so the exhaust cam picked up on 3 of its carriers, the timming pullt seized onto the bush it runs on and snapped the supporting bolt (very lucky it dont come out or it would have been a right off.



tilly

tilly

Oh my word! Nasty. I guess the oil light hadn't been hooked up for the test drive. How does it drive with the new engine?:)

it was wired but i think what happened was it came on we didnt see it, then it picked up oil again then we saw it when it came on the second time.

just been out for a test drive now and it all seems to be ok, still have so much to do before stonliegh, might look at making a new bonnet this afternoon if i can motivate myself.

tilly